Note: Descriptions are shown in the official language in which they were submitted.
.
19 In my U.S. Patent 3,999,743, there is descri-
bed a process and apparatus for recycling used asphalt-
21 aggregate composition in which the composition is
22 crushed and sized into different partiçle size ranges,
23 and introduced into a rotatable drum in which the com-
24 posi~ion is exposed directly to the flame and hot gases
~ . . .
~b '
P
1118157
of combustion. The specific process includes the introduction of
coarse and fine asphalt-aggregate composition particles into
separate and distin~tive heating zones in the ~rum. Because fine
or smaller asphalt containing composition particles will become
more easily heated as compared to coarse particles, the smaller
particles are introduced into the drum in a cooler zone in order
to prevent burning and degradation of the asphalt should it become
too hot, thereby resulting in significant smoke and other undesir-
able pollutants.
The present invention is directed to a process for
further improving the reduction of atmospheric pollutants given
off when heating asphalt-aggregate compositions during recycle
processing. The invention provides a process for producing
asphaltic concrete composition comprising introducing non-asphalt
containing aggregate particles in a hot zone of a rotatable drum
and gradually heating and advancing said aggregate toward an
output drum end, introducing particles of used asphaltic con-
crete comprising a mixture of asphalt and aggregate in said drum
downstream from said hot zone in a cooler temperature zone, and
gradually mixing and heating said non-asphalt containing aggregate
with said asphaltic concrete particles to produce said cor.lpo-
sition.
The drawing illustrates the apparatus of the invention
partially in section and partially cut away,
-- 2
1~18~j7
l showing the improved features of the modified appara-
2 tus, as well as illustrating the process according to
3 the invention.
4 Observing the drawing, there is illustrated
a rotatable dryer-type drum 10 having an outer cylin-
6 drical cover or surface 13, a stationary input end wall
7 47, and a stationary output end cover 45, enclosing the
8 hollow interior drum chamber. Secured on the interior
9 drum surface are a plurality of elongated lifters or
flights 18 extending substantially the length of the
11 drum interior. The purpose of the lifters is to assist
12 in mixing the aggregate and asphalt containing com~o-
13 sition by lifting it as the drum rotates. The mater-
14 ials then cascade from the rising lifters and fall
gravitationally to the bottom of the rotating drum
16 during the mixing and heating operation. The drum is
17 preferably inclined, as shown, so that aggregate intro-
18 duced at input end 16 will be drawn gradually gravita-
19 tionally toward output drum end 17. Thus, the input
end is elevated relative to the output end. The degree
21 of tilt may be varied to change the rate at which the
22 material flows through the drum.
23 The apparatus includes means for rotating
24 the drum, not shown, for example, a sprocket extending
around the drum surface 13 to which is secured a chain
~118~57
also meshing with gears and a motor or other drive means. The drum may be
supported on rollers and a suitable frame. Specific means for rotating and
supporting the drum are not a part of the invention and will be understood
by those skilled in the art. In the apparatus, hot gases of combustion pro-
duced by burner 12 are directed into the drum interior. The stationary out-
put end cover 45 may have a port 42 at the bottom thereof through which
heated and mixed composition is recovered. The final composition simply
falls through the port onto a conveyor 38. Other equivalent product recov-
ery means may be used and that shown is by way of example only. Both the
input end wall and output end cover are separated at least slightly from
their respective drum end surfaces to avoid interference with drum rotation.
On or near the top of the output end cover is a gas vent stack 50 which co-
operates with an exhaust fan 48 to draw the hot gases from burner 12 through
the drum and into the stack for venting and discharge into the atmosphere.
Alternatively, the gases and entrained dust may be directed to a dust col-
lector or knock out box with cooperating ducts.
The significant improvement of the process and apparatus of the
present invention is the manner in which the aggregate and recycle asphaltic
concrete particles are introduced into the heating and mixing drum and the
improved and advantageous result therefrom. It has been found that by in-
troducing the asphalt containing recyled particles in a cooler zone in the
apparatus as compared to the hot zone in which the aggregate particles are
introduced, heating efficiency is improved, asphalt degradation is substan-
tially decreased, if not eliminated, improved product is achieved, and air
pollution problems due to smoke, unburned hydrocarbons, noxious gases, and
fumes being vented into the atmosphere are obviated.
As shown in the drawing, aggregate particles 25, normally virgin
aggregate, are directed into drum 10 at the input end 16, just inside end
wall 47, and are directly exposed to hot gases from burner 12 in a first and
hottest drum zone. The aggregate is heated by the flame, including both
1~18~S7
luminous and nonluminous portions, radiant energy and hot gases of combus-
tion from burner 12J of any suitable conventional oil or gas burning type,
which will produce flame and hot gases and which are directed into the drum
interior through an orifice funnel or opening suitably located in the input
end wall 47. In this hot zone of the drum the environmental temperatures
may be, for example, between about 1,000 and about 3,000F, and higher
depending on the size and output of the burner as well as the dispersion of
flame and hot gases. The aggregate particles are lifted along the drum in-
terior surface and fall or cascade and tumble through ~he hot gas while they
gradually are heated and drawn forwardly toward the output drum end.
As also shown, the recycled asphalt-aggregate particles 35 are in-
troduced at some distance forwardly, downstream or toward the output end of
the apparatus from the input end, in a second and cooler zone. The specific
temperature of the cooler zone will depend on the distance from the burner
at which the asphalt containing particles are introduced as well as the out-
put or capacity of the burner used in the apparatus. Not only is the second
zone cooler because of its distance from burner 12, but a veil of cascading
aggregate particles in the hot zone forms a heat sink to significantly lower
the hot gas temperature and further shields the asphalt containing particles
from the radient energy of the flame. Although the second zone is cooler
than the hot zone at the input end, the asphalt-aggregate particles will be-
come heated sufficiently by exposure to the high temperature gases passing
through that zone and by being mixed with the heated aggregate. As the drum
rotates, the asphalt containing particles are lifted and cascade and mix
with the heated aggregated particles passing from the hot zone.
The preferred temperature in the cooler second zone will be below
about 800 F. Higher temperatures are preferably avoided, to prevent burning
of the more easily heated fines, which usually contain significant amounts
of asphalt. Such fines are the smaller asphalt containing particles in the
crushed asphaltic concrete material being recycled, which will pass a No. 8
57
United States Series sieve, and often comprise between about 20 and 60%, by
weight, of the recycle composition. Where substantial amo~mts of fines are
present, and especially where fine particle sizes are quite small, it may be
desirable to introduce the asphalt containing particles in the cooler zone
at temperatures below even 600F. Thus, the specific cooler zone temperature
will depend on the size and quantity of fines present.
Although one cooler zone is shown in the drawing, two or more sep-
arate zones may be used for introducing the recycled asphalt containing com-
position particles, each one being cooler than the next adjacent zone nearer
the input end. Thus, it will be understood that any number of a plurality
of zones or positions at which asphalt-aggregate composition particles are
introduced may be used, depending on the practical considerations of appar-
atus design, and separation and handling of different particle sizes de-
sired. Although one cool zone may be sufficient, two cooler zones may be
used,~a first one for coarse asphalt-aggregate particles, and a second even
cooler zone for introducing the finer particles. Such a plurality of cooler
zones as well as separation of different asphalt containing particle size
ranges is described in my aforesaid United States patent No. 3,999,743.
Moreover, if the apparatus is provided with means for introducing composi-
tion into more than two zones, only two zones need actually be used. Be-
cause the specific distance between zones i5 dependent on burner capacity,
particle sizes, and the like, the distance between input end wall 47 and the
second zone fed by chute 24, as shown in the drawing, is only for the pur-
pose of illustration and is not limiting. Thus, the distance between zones
may be selected to achieve the desired temperatures in the respective zones.
The amount of aggregate added in the recycling process will de-
pend on a number of variables. Normally, any amount, for example, up to
about 50% by weight or more, if desired, of aggregate, may be used, under-
standing that the final product will usually have between about 80 and
about 95% by weight aggregate, depending on paving or surface job specifi-
~8~57
cations and requirements. Since the combining of the virgin aggregate andasphalt in the process achieves a product having a higher percentage of
virgin mix, the amount of aggregate used will normally depend on the amount
of recycled composition available, its age and condition, aggregate si~es
available, cost requirements, and atmospheric pollution restrictions at the
job or plant site.
The aggregate or recycled asphalt-aggregate particles may be in-
troduced in any suitable manner, for example, a chute or hopper. A funnel
chute 30 is conveniently used at the stationary input end wall with agreg-
ate particles 25 introduced via conveyor 46. The particles will passthroùgh an opening in the end wall 47 so as to drop through the hot flame
and combustion gases of burner 12. Alternatively, for introducing aggreg-
ate, and/or for introducing asphalt-aggregate particles in the cooler drum
zone, a scoop means, secured to the drum exterior and cooperating with a
trough into which composition is placed, is illustrated in the drawing. As
shown, a trough 36 is stationarily positioned around the rotating cylindri-
c~l drum lO. A plurality of spaced ports 20 are located around the drum
surface, which ports open into the drum interior and communicate exterioTly
thereof. A scoop 31 is secured to the drum exterior overlying each port 20,
the scoops having a cavity which communicates with the port, and an edge
providing a surface for engaging composition as the drum rotates. Trough 36
extends around the drum covering the scoops and forms a cavity in which the
scoops are disposed and pass as the drum rotates. A chute 24 commlmicates
with trough 36, so that composition particles introduced through the chute
and into the trough are then picked up by the scoops and fall gravitational-
ly through ports 20 into the drum interior. The si~e and shape of the
trough should be such as to allow scoops to pass without resistance there-
through, and to pick up the composition particles introduced into the trough
cavity. The trough sides will preferably have edges which follow the gen-
eral shape of the drum exterior around which they extend but which side
-- 7 --
11~8157
edges are spaced at least slightly from the drum surface to avoid contactsince the drum rotates while the trough is maintained in a stationary posi-
tion. Means for introducing particles into the trough, for example, via
chute 24, is not especially critical and any convenient means may be used.
For example, a conveyor system 22 as shown may bring composition particles
up to chute 24 and which then passes into the hopper and trough.
The size and shape of the scoops and trough are not particularly
critical but are preferably such that the outer edge along the scoops are
of the same shape but slightly smaller than the interior wall of the trough.
The scoops are also preferably sloped so that particles will fall easily
along the scoop interior and into the ports gravitationally. More specific
details of the scoops, ports, and troughs used for the cooler zones may be
found in applicant's United States Patent No. 4,034,968, However, any
means may be used for introducing the particles in the different zones,
even including one or more conveyors extending into the drum from the out-
put end, for example, through output end cover 45. Thus, the means are not
critical and those shown being for the purpose of illustration.
Thè apparatus may incorporate one or more pipas 14, having one or
more openings 15, or similar means, for directing asphalt into the drum.
The asphalt is preferably added hot to have a more liquid consistency for
delivery through such a pipe, where it may be sprayed on the particles in
the drum to achieve the desired asphalt-aggregate product characteristics.
The asphalt is preferably added to the heated particulate mixture toward the
forward, output apparatus end away from burner 12, to avoid possible burning
or degradation of the asphalt. However asphalt should be introduced far
enough into the drum to allow sufficient mixing with the aggregate and re-
cycled asphalt-aggregate composition mixture gradually being drawn to the
output end, as it cascades and tumbles in the rotating, tilted drum. This
distance, as well as the asphalt quantities, will be readily determined by
3~ skilled artisans. Of course~ the quantity of asphalt added will depend on
-- 8 --
1~8157
the ratio of aggregate to recycled aspahlt containing material being mixed,
with greater aggregate quantities requiring more asphalt. Preferably the
pipe and asphalt delivery orifice 15 will extend into the drum to discharge
the liquid asphalt near the location at which the asphalt containing par-
ticles are introduced and as shown in the drawing. Again, asphalt is pref-
erably added as far into the drum as practical to give adequate mixing prior
to composition recovery at the output end. The pipe 14 may be extendable
to different lengths to provide flexibility in discharging liquid asphalt
at different selected locations.
The resulting composition recovered will have a preferred temper-
ature of at least about 200F and preferably above 225F or more. The de-
sired temperature can be achieved by varying the pitch or tilt of the drum,
its rate of rotation, burner heat, and material input rates. If desired,
aromatic hydrocarbon softening agent may also be used in the final product,
as described in my United States Patent No. 4,000,000. This flexibility of
the process and apparatus as well as other modifications and advantages
thereof within the purview of the invention will be evident to those skilled
in the art.
