Can an 80tph batch plant swallow half its weight in reclaimed pavement without losing its virgin output

2026-08-04

A standalone batch plant burns virgin aggregate, virgin bitumen, and virgin filler—every tonne of mix costs full new material. A contractor on a 20 km highway rehabilitation faces 30,000 tonnes of milled RAP piled at the roadside, charged a tipping fee to dump it, then buys 30,000 tonnes of new stone at $18/t. The arithmetic is brutal. The escape is not a new continuous recycler (too big, too dear); it is bolting a RAP hot-recycling module onto the existing 80 tph batch plant so the RAP enters the mixer at 50% ratio while the virgin side keeps running at its original rated tonnage. The LB1000 80TPH Asphalt Batch Mix Plant — 80 Tons Per Hour Asphalt Batching Plant Intermittent Forced Mixing Type Drying Drum Vibrating Screen Weighing System Baghouse Dust Collector PLC Automatic Control Burner Diesel Gas Coal For Highway Construction Municipal Road Airport Runway Hot Mix Asphalt Production Stationary Bitumen Mixing Plant With TS1510 RAP Hot Recycling Upgrade 50% Reclaimed Asphalt Pavement Ratio OEM Customized Manufacturer TTM Machinery Fujian Tietuo Henan Xinxiang Quanzhou Ttmmachinery is the native side of that pair; the TS1510 module is its recycling wing. But why does "incremental recycling" let the virgin 120 t/h line stay untouched while 80 t/h of RAP rides on top, how does indirect hot-air heating at 650–850℃ revive old bitumen without burning it, and what makes Fujian Tietuo (TTM Machinery, Quanzhou + Xinxiang dual bases) a recycling integrator rather than a drum welder that added a RAP hopper? Below is the full breakdown for highway rehabilitation contractors, municipal road maintenance bureaus, and asphalt producers in regulated markets evaluating a batch plant that turns roadside millings into 50% of the mix.

Why incremental RAP recycling beats a standalone recycler for an 80tph batch owner

Incremental Design = Virgin 120 t/h Untouched, RAP 80 t/h Added On Top. The TS1510 is not a replacement for the LB1000; it is an add-on island. The LB1000 keeps its cold feed, dryer, screen, hot bins, weigh bridge, and 2000 kg twin-shaft mixer running exactly as before (80 tph rated, 4 t/batch). The TS1510 contributes a separate RAP cold feed → RAP dryer drum (RGT80, Φ2.25×8 m) → RAP surge bin (10 t) → RAP pre-mixer (1000 kg, with rejuvenator injection) → RAP weigh hopper → slip chute into the existing LB1000 mixer. Net plant output becomes 140–160 t/h with 50% RAP ratio, and the native side never derates. A contractor who already owns an LB1000 adds $110k–140k of TS1510 modules instead of buying a 160 t/h combined recycler at $420k. The "incremental" word is the commercial hinge.
Indirect Hot-Air At 650–850℃ Revives Bitumen, Does Not Cremate It. Direct-flame RAP drums scorch the binder to 180℃+ at the particle skin, re-oxidizing the maltenes and producing a brittle black aggregate. The TS1510 RGT80 passes combustion gas (from a 9.8 MW burner) through a heat exchanger jacket; the RAP sees 650–850℃ hot air, never flame contact, peaking particle temperature at 110–130℃—enough to soften the old bitumen for metering, not enough to age it again. That is why Tietuo specifies "no open flame on RAP" as a patent point, not a marketing line. For a SMA rehabilitation where the reclaimed binder must keep its penetration grade, indirect heating is non-negotiable.
Blue Smoke → Virgin Dryer Secondary Burner. Heating RAP releases hydrocarbon vapors (the blue smoke) that would clog a baghouse in 3 weeks if exhausted directly. The TS1510 ducts that vapor-laden gas into the discharge end of the LB1000 virgin dryer, where the virgin burner (22 MW class) combusts the hydrocarbons at 1000℃+. Particulate load on the shared baghouse drops, and the legal stack emission stays <50 mg/Nm³ (GB 16297 / EU equivalent). A contractor in a sub-national jurisdiction with a 80 mg/Nm³ limit passes without a separate thermal oxidizer—saving $25k.
1000 kg RAP Pre-Mixer With Rejuvenator Before Main Mix. RAP out of the dryer is hot but the old binder is stiff. Dumping it straight into the 2000 kg main mixer leaves streaks of unreactivated binder. The TS1510 routes RAP + measured rejuvenator oil into a dedicated 1000 kg paddle pre-mixer for 12–15 s, so the softener penetrates before the virgin aggregate and virgin bitumen arrive. Final mix homogeneity improves; SMA and OGFC recipes become repeatable at 50% RAP, which a single-stage mixer cannot promise.
One Baghouse, 650 m², Serves Both Islands. The LB1000 standalone uses a 650 m² pulse-jet baghouse. When the TS1510 is added, the RAP dryer exhaust (post-secondary-combustion) joins the virgin exhaust ahead of the same baghouse. Because the blue smoke is already burned, the baghouse sees only mineral dust, so no upsize is needed—the 650 m² cloth handles 140–160 t/h combined. That shared-dust-collector trick is ~30% of the capex saving versus running two separate plants.
TTM Machinery / Fujian Tietuo Dual-Base OEM. TTM Machinery pages run from Henan Xinxiang (LB series batch plants) and Fujian Tietuo Machinery Co., Ltd., No. 1 Lujiang District Intelligent Equipment Industrial Park, Heshi Town, Quanzhou, Fujian (TS series RAP recycling, marketing@fjttm.com, +86 15805957318). The LB1000 and the TS1510 share PLC protocol, burner brand options, baghouse bags, and mixer liners—so one service engineer, one spare-parts kit. Not a RAP-trailer reseller; a road-machinery house that designs the native island and the recycling island to mate on a common foundation grid.

TTM Machinery / ttmmachinery.com supply context

From the node (TS1510-RAP-Recycling-Hot-Mix-Asphalt-Machine) + LB1000 sibling page + Fujian Tietuo spec sheet :

Native island: LB1000 80TPH Asphalt Batch Mix Plant — 80 t/h rated, 4 t/batch, 2000 kg mixer, 4-deck screen, 650 m² baghouse, dryer GT120 (Φ1.95×8 m, 22 MW burner)
Recycle island: TS1510 RAP Hot Recycling Machine — virgin 120 t/h, RAP 80 t/h, combined 140–160 t/h, RAP ratio 50%, RAP dryer RGT80 (Φ2.25×8 m, 9.8 MW indirect), RAP surge 10 t, RAP pre-mixer 1000 kg, secondary combustion in virgin dryer
Heating mode: Indirect hot-air 650–850℃ on RAP, no flame contact
Emissions: Shared baghouse <50 mg/Nm³; blue smoke to virgin dryer secondary burn
Burner fuel: Diesel / diesel-heavy-oil dual / coal powder / natural gas / oil-gas dual (both islands)
Control: PLC + HMI, recipe store, RAP ratio auto-correct by weigh feedback
Weighing accuracy: Static aggregate 0.5%, bitumen 0.2%, RAP 0.5%; dynamic ±2%
Footprint: Native island modular + recycle island modular, common H-beam foundation
Maker: TTM Machinery (Henan Xinxiang) + Fujian Tietuo Machinery (Quanzhou); brand TTM / Tietuo
URL: https://www.ttmmachinery.com/TS1510-RAP-Recycling-Hot-Mix-Asphalt-Machine

Key characteristics and application scope

Product Name: LB1000 80TPH Asphalt Batch Mix Plant (with TS1510 RAP recycling upgrade)
Alternate Terms: TTM LB1000 batch plant plus TS1510 RAP hot recycling island 50% reclaimed pavement, 80tph asphalt batching with incremental RAP module 140-160tph combined, Fujian Tietuo TS1510 indirect hot air RAP dryer 650-850C no flame contact, Quanzhou Xinxiang TTM asphalt plant RAP 50% ratio OEM, ttmmachinery.com LB1000 + TS1510 pair
Device class: Intermittent forced-mix batch plant + additive incremental RAP hot-recycling island (not continuous recycler, not standalone RAP drum)
Core Applications:
- Highway rehabilitation / mill-and-fill — 30k tonnes RAP on site, 50% ratio, virgin 80tph untouched, combined 160tph
- Municipal road maintenance — AC-13 wearing with 40% RAP, recipe switch per shift, baghouse compliant
- Airport apron overlay — SMA with rejuvenated RAP binder, indirect heating preserves penetration grade
- Provincial road reconstruction — RAP tipping fee avoided, new aggregate purchase cut 50%
- Asphalt producer green certification — ISO 14001 path via 50% recycled content mix
Companion logic: Same TTM PO pulls LB1500/LB2000 native islands, TS2015/TS4020 recycle islands, asphalt distributor, chip spreader, roller for a full rehab spread.

Application logic by buyer type

Highway Rehabilitation Contractor (SE Asia, 25 km mill-fill): Owns LB1000; adds TS1510 island. RAP 80 t/h at 50% ratio → 160 t/h combined. Saves 15,000 t new aggregate ($270k) + avoids 15,000 t RAP tipping ($45k). Coal burner on both islands. Payback on TS1510 module 14 months.
Municipal Maintenance Bureau (Africa): LB1000 + TS1510, diesel burner, RAP ratio 40% for AC-13, 50% for AC-20 base. PLC HMI in French. Baghouse <50 mg/Nm³ passes national EP limit.
Airport Overlay Specialist (Gulf): Gas burner, indirect RAP heating, rejuvenator dosing in 1000 kg pre-mixer, SMA 5% RAP-binder retained. 60 Hz electrical package.
Green-Cert Asphalt Producer (EU candidate): LB1000 + TS1510, 50% RAP, EN 13108-8 declared, EPD in progress, baghouse + secondary combustion for <20 mg/Nm³ local permit.

Procurement and spec checklist

When specifying LB1000 80TPH Asphalt Batch Mix Plant — 80 Tons Per Hour Asphalt Batching Plant Intermittent Forced Mixing Type Drying Drum Vibrating Screen Weighing System Baghouse Dust Collector PLC Automatic Control Burner Diesel Gas Coal For Highway Construction Municipal Road Airport Runway Hot Mix Asphalt Production Stationary Bitumen Mixing Plant With TS1510 RAP Hot Recycling Upgrade 50% Reclaimed Asphalt Pavement Ratio OEM Customized Manufacturer TTM Machinery Fujian Tietuo Henan Xinxiang Quanzhou Ttmmachinery:

✅ Native island — confirm LB1000 80 t/h, 2000 kg mixer, 4-deck screen, 650 m² baghouse unchanged.

✅ Recycle island — TS1510: RAP 80 t/h, RGT80 Φ2.25×8 m indirect, RAP surge 10 t, pre-mixer 1000 kg, RAP weigh hopper, slip chute to LB1000 mixer.

✅ RAP heating — indirect hot air 650–850℃; no flame contact; combustion gas to RAP drum jacket.

✅ Blue smoke — ducted to LB1000 virgin dryer discharge for secondary combustion.

✅ Ratio control — PLC auto-corrects RAP feed by weigh feedback to hold 50% ±2%.

✅ Rejuvenator — dosing pump to 1000 kg pre-mixer; confirm tank 1–2 t.

✅ Burner fuel — match both islands (diesel / gas / coal / dual); confirm 22 MW virgin + 9.8 MW RAP burner.

✅ Emissions — shared baghouse <50 mg/Nm³; optional <20 mg/Nm³ bag media upgrade.

✅ Foundation — common H-beam grid; RAP island adds 6 modules.

✅ Commercial — FOB Qingdao/Xiamen; TTM supplies both islands, one ERP number, one spare kit, erection 14 days for recycle island.

Conclusion: The 80tph batch plant becomes a 160tph half-recycled plant without losing its virgin soul

The LB1000 80TPH Asphalt Batch Mix Plant — 80 Tons Per Hour Asphalt Batching Plant Intermittent Forced Mixing Type Drying Drum Vibrating Screen Weighing System Baghouse Dust Collector PLC Automatic Control Burner Diesel Gas Coal For Highway Construction Municipal Road Airport Runway Hot Mix Asphalt Production Stationary Bitumen Mixing Plant With TS1510 RAP Hot Recycling Upgrade 50% Reclaimed Asphalt Pavement Ratio OEM Customized Manufacturer TTM Machinery Fujian Tietuo Henan Xinxiang Quanzhou Ttmmachinery does not get replaced when RAP shows up at the gate—it gets extended. The TS1510 island dries 80 t/h of millings in indirect 650–850℃ air, pre-mixes them with rejuvenator in a 1000 kg paddle tub, feeds them through a weigh hopper into the LB1000's existing 2000 kg mixer, and rides the same 650 m² baghouse after dumping its blue smoke into the virgin dryer's flame. Virgin output stays 80 t/h; combined output lands at 140–160 t/h with 50% RAP. Made by TTM Machinery (Xinxiang batch heritage) and Fujian Tietuo (Quanzhou recycling heritage) under one PLC roof, the pair ships with one spare-parts kit and one erection crew. Paired with a TTM asphalt distributor and chip spreader, it becomes a rehabilitation spread whose input cost drops by the tonne of RAP it swallows—not a new recycler, an old batch plant that learned to eat its own road.

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