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System and method for manufacturing asphalt products with recycled asphalt shingles

a technology of asphalt products and asphalt suspensions, applied in the field of asphalt products, can solve problems such as significant waste, and achieve the effect of reducing the moisture content of the ground shingles

Inactive Publication Date: 2014-01-16
HERITAGE ENVIRONMENTAL SERVICES
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The patent describes a method for manufacturing roofing products using a processed asphalt suspension. The method involves recycling shingle waste material by grinding it and removing metallic particles. The ground recycled shingles are then used to make the processed asphalt suspension by adding them to a heated slurry tank with virgin asphalt and an antifoam agent. The slurry is then pumped to a wet grinding mill, which reduces the size of mineral matter until it is a certain size. The technical effect of this patent is to provide a way to recycle shingle waste and make a high-quality processed asphalt suspension for use in roofing products.

Problems solved by technology

However, the high volume production of asphalt shingles leads to the production of significant waste, not only during the manufacture of the shingles, but also through removal (“tear-off”) of used shingles.

Method used

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  • System and method for manufacturing asphalt products with recycled asphalt shingles
  • System and method for manufacturing asphalt products with recycled asphalt shingles
  • System and method for manufacturing asphalt products with recycled asphalt shingles

Examples

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examples

Production of Processed Asphalt Suspension

[0036]There are three main components in the production of processed asphalt suspension: processing of the RAS input material (FIG. 1: 1-4, 9), mixing and processing the processed asphalt suspension (FIG. 1: 5-7, 9), and storage of the processed asphalt suspension (FIG. 1: 8). Each component of the process will be described in the following example.

Processing of the Shingle Input Material

[0037]The quality of the shingle input material is critical to the production of the processed asphalt suspension. Quality refers to the amount of debris present, moisture content, and the size of the RAS after grinding and processing.

[0038]Debris is defined as the non-shingle materials present due to the tear off process (nails, flashing, wood, packaging for new shingles, etc.). Debris present during the processing is detrimental to the performance of the pumps, hoses, storage tanks, and mills used during the processing; however, minor amounts of debris, su...

example 2

[0051]In the following examples, processed asphalt suspension compositions were prepared according to the following method. The RAS was mixed with virgin asphalt in a wetting tank and then transferred to a 400 liter jacketed attritor. The grinding media used in the attritor were 1 cm chrome steel ball bearings. The system was preheated to approximately 175° C. prior to adding the asphalt / RAS mixture. A nitrogen blanket was introduced to prevent oxidation during attriting. The mixing bar was rotated at about 100-150 rpm. The grinding media and the asphalt additive mixture were then mixed for about 5-12 minutes. During this process the grinding media provides shearing and impact forces, which reduce the asphalt additive particle size.

[0052]The processed asphalt suspension produced by the present invention is particularly useful for preparing roofing products. As mentioned above, such roofing products may include, but are not limited to, hot roofing adhesive, modified shingle adhesives...

example 4

Hot Mix Asphalt Paving Applications

[0065]The processed asphalt suspension as described in this present invention can additionally be used to create hot mix asphalt (HMA) pavements. The RAS can be mixed into virgin asphalt at levels between 5 and 65% of the total mixture. In one exemplary embodiment, the processed asphalt suspension contains 50% PG 58-28 with vacuum tower bottoms and 50% RAS. The properties of the processed asphalt suspension are shown in Table 5.

TABLE 550% PG 58-28 with vacuum tower bottomsDescription50% RASSoftening Point, ° F.135.524 hours Separation Test, ° F.0.548 hours Separation Test, ° F.225° C. Penetration42Solubility in TCE, % Soluble81.49Brookfield Rotational Viscosity @300° F., PaS0.469Brookfield Rotational Viscosity @325° F., PaS0.275Brookfield Rotational Viscosity @350° F., PaS0.150Original Binder DSR, G* / sin (delta), 76° C., Kpa0.96Original Binder DSR Fail Temp, ° C.75.6Original Binder DSR Phase Angle @76° C. 86.7RTFO Mass Loss, %−0.321RTFO Binder DSR,...

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Abstract

A method for manufacturing a processed asphalt suspension is provided. The method includes dry grinding shingle waste material to a particle size of less than 1 cm, forming ground recycled shingle material, introducing virgin asphalt into a heated slurry tank and mixing the ground recycled shingle material with the virgin asphalt in the heated slurry tank, forming a mixed asphalt slurry, introducing the mixed asphalt slurry into a wet grinding machine, and recovering a processed asphalt suspension comprising particles having a size no greater than about 200 microns. Roofing and paving products manufactured from the processed asphalt suspension are also provided.

Description

[0001]This non-provisional utility patent application claims priority to and the benefits of U.S. Provisional Patent Application Ser. No. 61 / 671,742 filed on Jul. 15, 2012 and to U.S. Provisional Application No. 61 / 728,891, filed on Nov. 21, 2012, each entitled System and Method for Manufacturing Roofing Products with Recycled Asphalt Shingles. Each application is incorporated herein by reference in its entirety.BACKGROUND[0002]The present invention relates generally to asphalt products, including processed asphalt compositions, that include recycled shingle material. More particularly the present invention relates to methods and apparatuses for forming processed asphalt suspensions, including mixing systems and process methods for creating performance enhanced asphalt compositions used in asphalt products.[0003]Asphalt roofing shingles make up over two-thirds of the residential roofing market for both new homes and roof replacements. However, the high volume production of asphalt s...

Claims

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Application Information

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IPC IPC(8): C08L95/00B02C19/00
CPCC08L95/00B02C19/0056C10C3/007C08L2555/22C08L2555/34C08L2555/52Y02A30/30E04D1/20C04B26/006C04B26/26C04B2111/00586C04B2111/0075E01C7/22E04D5/06
Inventor FRANZEN, MICHAEL R.TRUMBORE, DAVID CHARLESLEWANDOWSKI, LAURAND H.WISSEL, HERBBURKETT, JAMES E.HORNBACHER, BARRY GARRIETTPEREGRINE, CHRISTIANKRIECH, ANTHONY
Owner HERITAGE ENVIRONMENTAL SERVICES
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