Case Study: Astec, Inc. achieves significant energy savings and faster aggregate drying with Altair EDEM

Astec Employs Altair Edem™ to Redesign Aggregate Dryer for Energy Savings

Astec, Inc., a manufacturer of continuous and batch-process hot‑mix asphalt plants in Chattanooga, Tennessee, faced an energy‑intensive drying challenge: hundreds of tons/hour of wet aggregate must be lifted and veiled inside a rotating drum so heat transfer and drying are efficient, but direct observation of the process is nearly impossible. To redesign drum flighting for better veiling across varied aggregates and tonnages, Astec turned to Altair’s EDEM particle‑simulation software to virtually test new flight geometries and operating conditions.

Using Altair EDEM, Astec imported CAD of the dryer, developed a calibrated DEM material model, and used binning to quantify veil density and compare flight designs, leading to the new “V Flight.” The V Flight produced a much more even aggregate distribution, reduced drying time and fuel consumption, shortened the design cycle, and enabled faster field troubleshooting—delivering measurable energy savings and improved competitiveness for Astec customers.

Astec, Inc.

Andrew Hobbs

Chief CFD/ DEM Engineer