PREPARATION OF BITUMEN-CONTAINING ROAD SURFACE MATERIAL
20230365809 · 2023-11-16
Assignee
Inventors
Cpc classification
C08L95/00
CHEMISTRY; METALLURGY
C08L2555/84
CHEMISTRY; METALLURGY
C10C3/007
CHEMISTRY; METALLURGY
C08L2555/20
CHEMISTRY; METALLURGY
C08L2555/34
CHEMISTRY; METALLURGY
International classification
Abstract
The present disclosure sets out a method for processing bituminous road surfacing material from a road demolition. The bituminous road surfacing material is in the form of break out material and/or milled material. The following steps are carried out as part of the method: mixing the bituminous road surfacing material with water to form a mixture and adding a peroxide and/or a bicarbonate to the water and/or the mixture, in particular hydrogen peroxide and/or a bicarbonate.
Claims
1. A method of processing bituminous road surfacing material from a road demolition, the bituminous road surfacing material being in the form of at least one of break out material and milled material, the method comprising the steps of: mixing the bituminous road surfacing material with water to form a mixture; and adding at least one of a peroxide and a bicarbonate or at least one of hydrogen peroxide and bicarbonate to at least one of the water and the mixture.
2. The method according to claim 1, wherein the addition of the at least one of the hydrogen peroxide and the bicarbonate is controlled such that conglomerates of the bituminous road surfacing material are disaggregated.
3. The method according to claim 1, wherein the addition of the at least one of the hydrogen peroxide and the bicarbonate is carried out below level.
4. The method according to claim 1, further comprising the steps of mixing the bituminous road surfacing material unprocessed, directly with water to form a mixture.
5. The method according to claim 1, further comprising the steps of heating the mixture or heating the mixture to a temperature above 50° C. or heating the mixture to a temperature above 60° C.
6. The method according to claim 1, further comprising the steps of mechanically processing the mixture.
7. The method according to claim 1, wherein: the bituminous road surfacing material comprises grit, sand, filler and bituminous material, and the method is carried out until at least one of at least 80%, at least 90% and at least 95% of the grit is separated from the bituminous road surfacing material.
8. The method according to claim 1, wherein the method is carried out until a residual amount of bituminous material adhering to at least one of the grit and the grit, sand and filler is less than at least one of 3% by weight, less than 1% by weight, and less than 0.3% by weight.
9. The method according to claim 1, further comprising the step of collecting the bituminous material at a liquid surface of the mixture.
10. The method according to claim 1, wherein the bituminous road surfacing material further comprises at least partly bituminous material with a penetration value of at least one of less than 25, less than 20, and less than 15.
11. The method according to claim 1, wherein at least one of at least 30% by weight, least 50% by weight, and at least 75% by weight of the bituminous road surfacing material comprises a conglomerate size of more than 5 cm when mixed with the water.
12. The method according to claim 1, wherein a difference in density between the bituminous material floating on the surface and the mixture is increased by adding at least one first substance which influences the density, the first substance comprising at least one of an alkali, an acid, a salt and constituents of road surfacing material.
13. The method according to claim 1, wherein the bituminous road surfacing material comprises binders for achieving a bond between bituminous material and gravel, the binders comprising at least one of polymers, preferably styrene-butadiene-styrene amide esters.
14. The method according to any claim 1, wherein an adhesion between the bituminous material and the gravel of the bituminous road surfacing material is between 70% and 80%.
15. The method according to claim 1, wherein a proportion of VOC in the bituminous material is less than at least one of 1% by weight, 0.5% by weight, and 0.1% by weight.
16. (canceled)
17. The method according to claim 9, wherein the step of collecting is performed by means of flotation.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0200] Further advantages, features, and details of the various embodiments of this disclosure will become apparent from the ensuring description of a preferred exemplary embodiment and with the aid of the drawings. The features and combinations of features recited below in the description, as well as the features and feature combination shown after that in the drawing description or in the drawings alone, may be used not only in the particular combination received, but also in other combinations on their own, without departing from the scope of the disclosure.
[0201] The drawings used to explain the embodiments of the presently disclosed invention depict the following:
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[0213] In the figures, the same components are given the same reference symbols.
DETAILED DESCRIPTION OF THE INVENTION
[0214] As used throughout the present disclosure, unless specifically stated otherwise, the term “or” encompasses all possible combinations, except where infeasible. For example, the expression “A or B” shall mean A alone, B alone, or A and B together. If it is stated that a component includes “A, B or C”, then, unless specifically stated otherwise or infeasible, the component may include A, or B, or C, or A and B, or A and C, or B and C, or A and B and C. Expressions such as “at least one of” do not necessarily modify an entirety of the following list and do not necessarily modify each member of the list, such that at least one of “A, B, and C” should not be understood as including only one of A, only one of B, only one of C, or any combination of A, B, and C.
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[0222] The experiments performed on the separation process are described below. In each of the following experiments, milled material from a road pavement was used as secondary raw material.
[0223] In the first experiment, 5 g of milled material from a road surface was crushed and mixed with 10 ml of 3% hydrogen peroxide in a container. The container was placed in a pressure cooker containing water and boiled for 5 minutes. A foam with 1 g dry mass, including bitumen and filler, was found on the hydrogen peroxide solution in the container.
[0224] In a second experiment using a water bath heater, 300 g of milled material from a road pavement was crushed and placed in a beaker. The milled material was mixed with 500 ml of a 3% hydrogen peroxide solution. The beaker was heated to 60 to 65° C. in a water bath. Bubbles formed, which carried the bitumen to the surface, where a foam was formed. When increased to a temperature of 80° C., the process was more efficient, and at 95° C. the separation proceeded for 10 minutes under very good conditions, achieving good separation of the bituminous material from the matrix.
[0225] In a third test, 6.8 kg of milled material from a road pavement was crushed and placed in a container. The milled material was covered with water. The mixture was then heated to 60° C. and 100 ml of 35% hydrogen peroxide solution was added. The mixture was stirred and the foam was skimmed off at regular intervals. After four hours of skimming and addition of hydrogen peroxide (every 30 minutes), the process was stopped. The matrix was almost completely freed from bituminous material. The matrix weighed 4.1 kg and the bituminous material weighed 1.6 kg. Fine residues in the water made up the remainder of the milled material. Since the road pavement contains only about 6% bituminous material, only about 400 g of bituminous material is in the 1.6 kg, the rest is likely to be filler, dust, fragments, etc. The large amount of fine material can be attributed to the crushing of the milled material.
[0226] In a fourth test, a block of 3.8 kg of milled material from a road pavement was used. This was broken into pieces of 40 to 80 mm diameter. The broken pieces were covered with water in a container and heated up to a temperature of 60° C. The water was used to heat up the material. During 2.5 hours, 160 ml of 35% hydrogen peroxide solution was continuously added. The conglomerates were disaggregated in a few minutes. The foam was skimmed off regularly. The mixture was boiled up. The remaining matrix was bitumen-free and weighed 2.9 kg. The bituminous material weighed 0.7 kg, with the filler accounting for 165 g. The theoretical amount of bituminous material was 230 g, with filler and dust accounting for 228 g-about 6% of the original amount of milled material.
[0227] These experiments have shown that the crushing process can have the disadvantage that dust accumulates in the bituminous material. Thus, by using fragments of road pavement directly, bituminous material with greater purity can be obtained.
[0228] In a fifth experiment, on the one hand the density of water was increased in order to increase the buoyancy of the bituminous material in water. Bituminous material in road pavements typically has a higher density than water, namely between 1.01 and 1.05 kg/L. Thus, there is a risk that the bituminous material will collect at the bottom of the tank after it is released from the matrix. This effect can be counteracted by adding a density-increasing salt or a density-increasing liquid. The salts may be sodium chloride, magnesium chloride, potassium chloride, sodium carbonate or sodium nitrate. For example, glycerol or the like may be used as the liquid. The separation can also be carried out in pure glycerol.
[0229] In a sixth experiment, 5 kg of milled material from a road surface was used and mixed with 7.5 L of water without table salt. The mixture was heated to 95° C. and stirred with a paddle mixer. Subsequently, 100 g of sodium bicarbonate in powder form was added every 15 minutes. After 6 additions and 2 hours of reaction time, 1.3 kg of bituminous material was obtained at the water surface. Most of the 3.7 kg matrix was separated from the bituminous material. The water contained suspended solids.
[0230] These experiments show that the process can be carried out with different substances (bicarbonates, acetic acid, peroxides, percarbonates, etc.).
[0231] In a seventh experiment, 5 kg of milled material was mixed with 5 liters of water and rubbed with a powerful mixer for two hours (abrasion method). After two hours, the grit (gravel) were tested. The grit contained some bitumen in the concave areas. The abrasion contains the large part of bitumen.
[0232] Now, about 10 wt. % CaCl.sub.2) was dissolved in 600 ml of the above residual water containing filler and sand with bituminous material, and 1 ml of 35 wt. % H.sub.2O.sub.2 was added and heated. A bituminous residue was extracted and the sand and filler were decanted. After 24 hours, this part represented 180 ml and no longer contained bitumen. 200 g of grit, which contained a little bitumen, was again treated in 600 ml of water with 1 ml of H.sub.2O.sub.2 and heated. After the treatment, the grit was cleaned of bitumen.
[0233] In another experiment, 400 ml of the above residual water, which contained filler and sand with bituminous material, was mixed with 300 ml of water and blended in a blender (which are also used to blend smoothies). Mixing creates many air bubbles in the suspension, which carry the bituminous material to the surface in the form of a foam. Sand and filler, on the other hand, sediment due to their higher density. The process works without chemical additives and also without additives to increase the density of the water.
[0234] These variations show that it is possible to combine different techniques (abrasion, fractionation, etc.) to obtain the best efficiency (efficiency, purity, etc.).
[0235] In an eighth experiment, approximately 80 kg of milled material was heated and mixed in 200 L of water at 90° C. During the process, 10 ml/min of H.sub.2O.sub.2 was injected through a pump. To increase the density of the water, 25 kg of sodium carbonate was added. After two hours of reaction, 10 kg of bituminous residue and 70 kg of mineral were collected. This demonstrated that purification could be carried out without chloride salt.
[0236] In a ninth experiment, 10 kg of milled material was placed in 20 L of water and heated with sodium bicarbonate. The bituminous material rose to the surface but fell back down because the density difference was not sufficient to keep the bituminous material on the water surface. To recover the residue on the water surface, a stream of carbon dioxide (CO.sub.2) was introduced at the bottom of the vessel, causing the bituminous material to convect to the surface where it could be collected. This experiment shows that it is possible to collect the bituminous residue on the liquid surface without increasing the density of the water with salt or sugar.
[0237] In a tenth experiment, the dried bituminous material was post-processed to extract the bitumen from the filler and sand. In fact, the bituminous residue may contain 25% to 33% bitumen by weight, while the remainder comprises small mineral particles. The bituminous material was placed in a container with water and post-processed by vigorous mixing with a mixer. This separated the bitumen from the filler and sand. By adding salt to the water, the bitumen floated on the surface while the mineral part sedimented. This allowed the bitumen to be concentrated.
[0238] In the case of road pavements, the bituminous material intentionally adheres particularly strongly to the fillers, to the sand and grit. A layer thickness can reach several hundred micrometers. As a result, the bituminous material is removed layer by layer from the matrix during the process. This in turn means that rapid addition of a reactive substance, in particular a release agent, for example a peroxide, can have the following disadvantages: [0239] an excessively violent reaction is triggered, producing a large amount of foam. With the gas bubbles, not only the bituminous material, but also a lot of sand and filler is carried upwards, into the foam; [0240] the peroxide can also react with already separated bituminous material, oxidizing the bituminous material. Thus, the peroxide is used inefficiently.
[0241] These problems can be addressed by two measures. On the one hand, the peroxide can be added in doses so that a low concentration is always present. Furthermore, it is advantageous if the peroxide is added in the area of the secondary raw material, i.e. in the area of the bottom of the container. This can be done, for example, via a dip tube.
[0242] In this fifth experiment, 280 kg of milled material from a road pavement was used and mixed with 250 L of water and 25 kg of common salt. The mixture was heated to 60° C. and stirred with a paddle mixer. Subsequently, 100 ml of 35% hydrogen peroxide solution was added via a dip tube after every 10 minutes. Alternatively, the addition can also be carried out continuously via a pump. After 14 additions of 100 ml hydrogen peroxide solution a 35% and 2 hours reaction time as well as 1 hour material collection, 45 kg bituminous material was obtained at the water surface. Most of the matrix was separated from the bituminous material. The salt water contained suspended solids.
[0243] The mode of operation is not fully understood. It is possible that the introduction of the peroxide solution results in a relatively acidic pH, which dissolves lime residues and releases bicarbonate. The bicarbonate, in turn, acts together with peroxide as a powerful cleaning agent, which in turn can effectively separate the bituminous material from the matrix.
[0244] In another preferred process, the use of catalysts accelerates the formation of gas bubbles, whereby the temperature of the mixture in the vessel can be kept lower. This can save heating time on the one hand and heating energy on the other. This results in a particularly efficient and cost-effective separation process.
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[0246] In another embodiment, the catalyst is mixed with the water directly in the vessel, which also eliminates the need for the conduit 231.
[0247] The materials (milled material, catalyst, etc.), which are suspended or dissolved in the water, can be introduced using various technical devices, for example, scraper, vibrator, inclined plane, mixer, inclined rotating drum, conveyor belt, screw conveyor, etc.
[0248] In another embodiment of the process, instead of the catalyst solution, superheated steam is fed via line 231 into the local area of the outlet opening of line 221. This allows a gas bubble generating substance, for example the peroxide, to be heated locally to accelerate decomposition.
[0249] In another embodiment, a catalyst solution is heated, thereby accelerating the decomposition reaction simultaneously by heat and the catalyst. This embodiment may be used for typically more reactive substances.
[0250] While in the first embodiment the two conduits 221 and 231 are parallel, in a further embodiment they may be coaxial, as an inner tube and an outer tube. Further, the pipelines, whether routed in parallel or coaxially, may also be connected from an outer side of the container 210 to openings in the bottom of the container. This can be advantageous, since it means that an agitation process in the container 210 is not hindered by pipes. Further, the lines may also terminate in a common end pipe.
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[0252] In a first experiment, 30 kg of milled material is added to a tank with an agitator containing 40 L of water at 18° C. 4 kg of Na.sub.2CO.sub.3 is added to obtain sufficient density for the bitumen extract to float on the water after separation. Two tubes are connected in parallel to dispense a 35% H.sub.2O.sub.2 solution and a 40% FeCl.sub.3 solution at a flow rate of 100 microliters/minute. The mixture of the two reagents generates gas bubbles even at low temperature, which are produced by the decomposition of the peroxide. After two hours, a bituminous extract weighing several kilograms is collected and dried in powder form. The remaining material consists of sand and pebbles, which are cleaned of their bitumen. Furthermore, a brown residue of oxidized iron is visible, but this can be easily rinsed out. The water temperature only rises to around 22° C. during the reaction due to the endothermic nature of the peroxide decomposition.
[0253] In another experiment, peroxide decomposition was accelerated by local heating: About 30 kg of milled material is mixed with 40 L of water at 15° C. in a reactor with a stirrer. 4 kg of Na.sub.2CO.sub.3 is added to obtain sufficient density for the bitumen extract to float on the water after separation. Two tubes are inserted into each other. With the inner tube, a 35% H.sub.2O.sub.2 solution is added to the reactor at a flow rate of 100 microliters/minute. Boiling water is added between the inner tube and the outer tube. As it exits the reactor, the mixture of hydrogen peroxide and hot water generates high temperature gas bubbles. After two hours, a bituminous extract weighing several kg is collected and dried in powder form. The remaining material consists of sand and pebbles that have been cleaned of their bitumen.
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[0255] At high temperatures (typically above 35° C.), the bitumen floats on the water after separation and can be separated by skimming. At low temperatures, the bitumen basically precipitates and sinks to the bottom of the reactor. Below 35° C., the bitumen has a density of about 1.03 t/m3. To achieve sufficiently efficient separation of the bitumen via the liquid surface, the density of the liquid should be, for example, 1.045 t/m3. Now, in order to achieve floating of the bitumen on the surface of the water even at low temperatures, the density of the water can be increased to or above this value by additives such as salt, sugar, suspended solids, sludge, etc. This can be achieved, for example, by adding at least 5% Na.sub.2CO.sub.3. Since at the same time the sand and gravel have a higher density, the bitumen can thus be effectively separated from the sand and gravel at low temperature and simply skimmed off at the water surface.
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[0258] If the reaction is carried out in cold water (below 35° C.), it is also possible to dispense with increasing the density of the liquid. In this case, the bitumen can sink to the bottom of the 610 reactor along with the minerals (sand, gravel). The sand and gravel can be removed with a mineral-specific auger 620. The filler can be flushed out with the reagent foam via a conduit 630. The bituminous residue may be discharged from reactor 610 at the end of the separation process or by a special mechanical means (e.g., chain scraper).
[0259] In another embodiment, the separated bitumen is kept in suspension, for example by adjusting the density or by a suitable stirring method. During the process, the liquid containing the suspended bitumen is now pumped off and separated from the liquid in a separate container, for example by decanting. The separated liquid can be returned to the reactor. This allows the bitumen to be removed from the liquid in a continuous process. Sand/gravel and the filler can also be continuously removed from the liquid, for example via a mineral-specific screw conveyor. Thus, the entire process can be carried out continuously.
[0260] In another experiment, 3 tons of sands contaminated with hydrocarbons (C10-C40 (number of carbon atoms per molecule); 320 mg/kg) and total organic carbon (TOC: 8100 mg/kg) were treated in a 9000 liter tank filled with water at 80° C. and equipped with an agitator; 25 L of peroxide 35% was added below the water level and the whole was mixed for 15 minutes. After a few minutes, a foam could already be seen on the water level, containing fine material, which overflowed from the tank and was collected.
[0261] After the experiment, the sand remaining in the tank and the fine material that overflowed from the tank were analyzed: [0262] The sands contained a hydrocarbon concentration of 170 mg/kg (C10-C40) and a TOC value of less than 5,000 mg/kg; [0263] The fine material discharged as foam contained enriched hydrocarbons at 5,400 mg/kg and a TOC value of 110,000 mg/kg.
[0264] The analyses show that the treatment works and reduces the contamination by a factor of 2 under the above conditions, making these sands suitable for use in construction.
[0265] This shows that the process concentrates the contaminants in the fine material, which exits as foam, and significantly reduces or eliminates the contaminants on the sand.
[0266] Small scale trials have also shown that PAH contaminated soils can be cleaned using the process of the present invention. PAH-contaminated soils can originate from roadsides, but also from dust precipitation from industrial processes, such as polluted sites near aluminum plants that were operated in the past using the Sorderberg process.
[0267] In a post-treatment stage, the materials (sand, gravel, bitumen, etc.) can be rinsed to remove residues of the additives (e.g. common salt, ferric chloride, peroxide, etc.). The bitumen may be dewatered, in particular, for example, pressed, compacted, heated.
[0268] In summary, it can be stated that, according to the invention, a process for separating bituminous material from a secondary raw material is created, which can be carried out particularly effectively and with little effort.
[0269] Since the devices and methods described in detail above are examples of embodiments, they can be modified to a wide extent by the skilled person in the usual manner without departing from the scope of the invention. In particular, the mechanical arrangements and the proportions of the individual elements with respect to each other are merely exemplary. Some preferred embodiments of the apparatus according to the invention have been disclosed above. The invention is not limited to the solutions explained above, but the innovative solutions can be applied in different ways within the limits set out by the claims.