Method of making sulfur extended asphalt modified with crumb rubber

Abstract

The present invention relates to asphalt compositions. The present invention provides for a sulfur rubber asphalt binder composition that includes a base asphalt having a softening point, elemental sulfur, and a crumb rubber material. The crumb rubber material is combined with the base asphalt and the elemental sulfur to create the sulfur rubber asphalt binder composition. The crumb rubber material is present in the sulfur rubber asphalt binder in an amount effective to increase the softening point as compared to the softening point of the base asphalt.

Claims

1. A method of making a sulfur rubber asphalt binder composition comprising the steps of: mixing a crumb rubber material with a base asphalt at a first predetermined temperature in a shear blender for first predetermined amount of time to create an asphalt crumb rubber mixture; placing the asphalt crumb rubber mixture in a sealed container in an oven at the first predetermined temperature for a second predetermined amount of time to create an aged asphalt crumb rubber mixture, wherein the asphalt crumb rubber mixture is cured and reacted in the sealed container free of external mixing for the second predetermined amount of time; adding elemental sulfur to the aged asphalt crumb rubber mixture and mixing for a third predetermined amount of time at a second predetermined temperature such that intimate mixing of the elemental sulfur and the asphalt crumb mixture is achieved.

2. The method of claim 1, wherein the elemental sulfur is in powder form.

3. The method of claim 1, where the elemental sulfur is in liquid form.

4. The method of claim 1, where the first predetermined temperature is about 180 C.

5. The method of claim 1, where the second predetermined temperature is about 145 C.

6. The method of claim 1, where the first predetermined amount of time is about 2 minutes.

7. The method of claim 1, where the second predetermined amount of time is about 2 hours.

8. The method of claim 1, where the third predetermined amount of time is about 20 minutes.

9. The method of claim 1, wherein the first predetermined amount of time is in a range of about 1 minutes to about 5 minutes, the second predetermined amount of time is in a range of about 90 minutes to about 150 minutes and the third predetermined amount of time is in a range of about 15 minutes to about 25 minutes.

10. A method of making a sulfur rubber asphalt binder composition comprising the steps of: mixing a crumb rubber material with a base asphalt at a first predetermined temperature in a shear blender for first predetermined amount of time to create an asphalt crumb rubber mixture; placing the asphalt crumb rubber mixture in a sealed container in an oven at the first predetermined temperature for a second predetermined amount of time to create an aged asphalt crumb rubber mixture; and adding elemental sulfur to the aged asphalt crumb rubber mixture and mixing for a third predetermined amount of time at a second predetermined temperature such that intimate mixing of the elemental sulfur and the asphalt crumb mixture is achieved; where the asphalt is about 54 weight percent, the elemental sulfur is about 40 weight percent and the crumb rubber material is about 6 weight percent, each by weight of the sulfur rubber asphalt binder composition.

11. A method of making a sulfur rubber asphalt binder composition comprising the steps of: mixing a crumb rubber material with a base asphalt at a first temperature in a shear blender for first amount of time to create an asphalt crumb rubber mixture; maintaining the asphalt crumb rubber mixture in a sealed container in an oven at the first temperature for a second amount of time to create an aged asphalt crumb rubber mixture wherein the asphalt crumb rubber mixture is cured and reacted in the sealed container free of external mixing for the second amount of time; and introducing elemental sulfur to the aged asphalt crumb rubber mixture and mixing for a third amount of time at a second temperature such that the sulfur rubber asphalt binder composition forms; where the elemental sulfur is in a range of from about 30 to about 50 weight percent and the crumb rubber material is in a range of from about 1 to about 6 weight percent, each by weight of the sulfur rubber asphalt binder composition.

12. The method of claim 11, where the sulfur rubber asphalt binder composition and the base asphalt each have a softening point temperature, and the softening point temperature for the sulfur rubber asphalt binder composition is greater than that of the base asphalt.

13. The method of claim 11, where: the elemental sulfur is in an amount of about 40 weight percent and the crumb rubber material is in a an amount selected from the group consisting of 1 or 2 weight percent, each by weight of the sulfur rubber asphalt binder composition; and the sulfur rubber asphalt binder composition and the base asphalt each have a penetration grade value, and the penetration grade value for the sulfur rubber asphalt binder composition is less than that of the base asphalt.

14. The method of claim 11, where: the elemental sulfur is in a an amount selected from the group consisting of 30, 40 and 50 weight percent by weight of the sulfur rubber asphalt binder composition; the crumb rubber material is in in an amount selected from the group consisting of 1, 2, 4 and 6 weight percent by weight of the sulfur rubber asphalt binder composition; the base asphalt is an amount so that the sum of the elemental sulfur, the crumb rubber, and the base asphalt totals 100 weight percent by weight of the sulfur rubber asphalt binder composition; and the sulfur rubber asphalt binder composition and the base asphalt each have a Performance Grade temperature range, and the Performance Grade temperature range for the sulfur rubber asphalt binder composition is broader than that of the base asphalt.

15. The method of claim 11, where: the elemental sulfur is in a an amount selected from the group consisting of 30, 40 and 50 weight percent by weight of the sulfur rubber asphalt binder composition; the crumb rubber material is in in an amount selected from the group consisting of 1, 2, 4 and 6 weight percent by weight of the sulfur rubber asphalt binder composition; the base asphalt is an amount so that the sum of the elemental sulfur, the crumb rubber, and the base asphalt totals 100 weight percent by weight of the sulfur rubber asphalt binder composition; and the Performance Grade of the sulfur rubber asphalt binder composition is selected from the group consisting of 70-10, 76-10, 82-10 and 88-10.

16. The method of claim 11, where: the elemental sulfur is in a an amount of about 30 weight percent by weight of the sulfur rubber asphalt binder composition; the crumb rubber material is in in an amount selected from the group consisting of 1, 2, 4 and 6 weight percent by weight of the sulfur rubber asphalt binder composition; the base asphalt is an amount so that the sum of the elemental sulfur, the crumb rubber, and the base asphalt totals 100 weight percent by weight of the sulfur rubber asphalt binder composition; and the sulfur rubber asphalt binder composition and the base asphalt each have a set of complex modulus (G*) values associated with a range of temperature values in a range from 64 C. to 76 C., and where each G* value for the sulfur rubber asphalt binder composition is greater at each temperature value within the range of temperature than that of the base asphalt.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows the penetration grade test summary of sulfur/asphalt/crumb rubber binders.

DETAILED DESCRIPTION OF THE INVENTION

(2) Although the following detailed description contains many specific details for purposes of illustration, it is understood that one of ordinary skill in the art will appreciate that many examples, variations, and alterations to the following details are within the scope and spirit of the invention. Accordingly, the exemplary embodiments of the invention described herein and provided in the appended figures are set forth without any loss of generality, and without imposing limitations, on the claimed invention.

(3) In some embodiments, the invention provides for a sulfur rubber asphalt binder composition that includes a base asphalt having a softening point, elemental sulfur, and a crumb rubber material. The crumb rubber material is combined with the base asphalt and the elemental sulfur to create the sulfur rubber asphalt binder composition. The crumb rubber material is present in the sulfur rubber asphalt binder in an amount effective to increase the softening point as compared to the softening point of the base asphalt.

(4) In some embodiments, the sulfur rubber asphalt binder composition ranges from about 45% by weight to 80% by weight base asphalt. In some embodiments, the composition ranges from about 55% by weight to 75% by weight base asphalt. In some embodiments, the composition is about 45% by weight base asphalt. In some embodiments, the composition is about 50% by weight base asphalt. In some embodiments, the composition is about 55% by weight base asphalt. In some embodiments, the composition is about 60% by weight base asphalt. In some embodiments, the composition is about 65% by weight base asphalt. In some embodiments, the composition is about 70% by weight base asphalt. In some embodiments, the composition is about 75% by weight base asphalt. In some embodiments, the composition is about 80% by weight base asphalt.

(5) In further embodiments, the sulfur rubber asphalt binder composition ranges from about 10% by weight to 50% by weight elemental sulfur. In further embodiments, the elemental sulfur is up to 50% by weight. In further embodiments, the sulfur rubber asphalt binder composition is about 5% by weight elemental sulfur. In further embodiments, the sulfur rubber asphalt binder composition is about 10% by weight elemental sulfur. In further embodiments, the sulfur rubber asphalt binder composition is about 15% by weight elemental sulfur. In further embodiments, the sulfur rubber asphalt binder composition is about 20% by weight elemental sulfur. In further embodiments, the sulfur rubber asphalt binder composition is about 25% by weight elemental sulfur. In further embodiments, the sulfur rubber asphalt binder composition is about 30% by weight elemental sulfur. In further embodiments, the sulfur rubber asphalt binder composition is about 35% by weight elemental sulfur. In further embodiments, the sulfur rubber asphalt binder composition is about 40% by weight elemental sulfur. In further embodiments, the sulfur rubber asphalt binder composition is about 45% by weight elemental sulfur. In further embodiments, the sulfur rubber asphalt binder composition is about 50% by weight elemental sulfur. In further embodiments, the elemental sulfur is in solid form. In some embodiments, the elemental sulfur is in powder form. In other embodiments, the sulfur is in liquid form.

(6) In further embodiments, the sulfur rubber asphalt binder composition ranges from about 1% by weight to 6% by weight crumb rubber material. In further embodiments, the sulfur rubber asphalt binder composition is about 1% by weight crumb rubber material. In further embodiments, the sulfur rubber asphalt binder composition is about 2% by weight crumb rubber material. In further embodiments, the sulfur rubber asphalt binder composition is about 3% by weight crumb rubber material. In further embodiments, the sulfur rubber asphalt binder composition is about 4% by weight crumb rubber material. In further embodiments, the sulfur rubber asphalt binder composition is about 5% by weight crumb rubber material. In further embodiments, the sulfur rubber asphalt binder composition is about 6% by weight crumb rubber material.

(7) In a further embodiment, the asphalt is about 58% by weight, elemental sulfur is about 40% by weight, and the crumb rubber material is 2% by weight.

(8) In another aspect, the invention provides for using the sulfur rubber asphalt binder composition to make an asphalt composition that also includes an aggregate material and a filler.

(9) In further embodiments, the aggregate material is a gravel, sand, or stones. In some embodiments, the filler is a mineral filler.

(10) The asphalt compositions of the present invention have improved properties over those of the base asphalt alone. For instance, in some embodiments, the asphalt composition has greater temperature resistance than that of the base asphalt alone. In further embodiments, the asphalt composition has improved waterproofing properties as compared to that of the base asphalt alone. In other embodiments, the asphalt composition has improved damp proofing properties as compared to that of the base asphalt alone.

(11) The asphalt compositions described herein can be used for a number of different purposes, including applications where improved waterproofing and damp proofing are desired. In some embodiments, the asphalt composition is used in paving applications. In some embodiments, the asphalt composition is used in asphalt concrete pavement. In other embodiments, the asphalt is used in roofing applications. The asphalt compositions can be used in any applications where the use of a sulfur extended asphalt would be beneficial.

(12) In another aspect, the invention provides for a method of making the sulfur rubber asphalt binder composition. The crumb rubber material is mixed with the base asphalt at a first predetermined temperature in a high shear blender for a first predetermined amount of time to create an asphalt crumb rubber mixture. The asphalt crumb rubber mixture is then placed in a sealed container in an oven at the first predetermined temperature for a second predetermined amount of time. The elemental sulfur is added to the asphalt crumb rubber mixture and mixed for a third predetermined amount of time at a second predetermined temperature such that intimate mixing of the elemental sulfur and the asphalt crumb mixture is achieved.

(13) In some embodiments, the first predetermined temperature ranges from about 170 C. to about 190 C. In further embodiments, the first predetermined temperature is about 180 C. In the first predetermined temperature range, the crumb rubber typically swells.

(14) In some embodiments, the second predetermined temperature ranges from about 140 C. to about 150 C. In further embodiments, the second predetermined temperature is about 145 C. In the second predetermined temperature range, the sulfur is blended with the asphalt.

(15) In some embodiments, the first predetermined amount of time ranges from about 1 minute to 5 minutes. In further embodiments, the first predetermined amount of time is about 2 minutes. In the first predetermined amount of time, the crumb rubber is mixed with asphalt before it swells.

(16) In some embodiments, the second predetermined amount of time ranges from about 90 minutes to 150 minutes. In further embodiments, the second predetermined amount of time is about 120 minutes. During the second predetermined amount of time, the crumb rubber typically swells.

(17) In some embodiments, the third predetermined amount of time ranges from about 15 minutes to 25 minutes. In further embodiments, the third predetermined amount of time is about 20 minutes. In the third predetermined amount of time, sulfur is blended with the asphalt crumb mixture.

EXAMPLES

(18) The following tests were carried out on various asphalt compositions as reported below. Penetration tests were conducted in accordance with ASTM D5, softening points tests were conducted in accordance with ASTM D36, and performance grading was conducted.

(19) TABLE-US-00001 TABLE 1 Softening Points and Pentration Grade Analyses Softening point Sample # Sample composition ( C.) Penetration grade 1 Pure asphalt 52.4 52 2 R 1%, S 40% and A 59% 59.5 46.2 3 R 2%, S 40% and A 58% 65.5 44.3 4 R 0%, S 40% and A 60% 56.5 50.4 5 R 0%, S 50% and A 50% 60.3 48.5 S: Sulfur, R: Crumb rubber, A: Asphalt

(20) The results of the softening point and penetration grade analyses are presented in Table 1. The results showed that the increase in rubber composition increased the softening point while decreasing the penetration grade. The increase in softening point indicated that the composition had greater temperature resistance and an increased range of applications. The increases in penetration grade increased the stiffness and also increased the range of applications.

(21) TABLE-US-00002 TABLE 2 Performance Grades (PGs) for Pure Asphalt and Sulfur/Asphalt/Rubber Binder Compositions Percentages of different components Crumb Sample # Sulfur % Asphalt % rubber % PG 1 0 100 0 64-10 2 30 70 0 64-10 3 40 60 0 64-10 4 20 79 1 64-10 5 20 78 2 64-10 6 20 76 4 70-10 7 20 74 6 70-10 8 30 69 1 70-10 9 30 68 2 70-10 10 30 66 4 76-10 11 30 64 6 76-10 12 40 59 1 76-10 13 40 58 2 76-10 14 40 56 4 76-10 15 40 54 6 82-10 16* 50 49 1 76-10 17 50 48 2 76-10 18 50 46 4 82-10 19 50 44 6 88-10

(22) Table 2 represents the Performance Grade (PG) test summary of pure asphalt and different sulfur/asphalt/rubber binder compositions. The PG test was performed in accordance with the Strategic Highway Research Program (SHRP) method AASHTO MP1-98. The data showed that sample number 16 had the greatest amount of sulfur content and the minimum amount of additive to achive the PG76-10 rating. The result showed that an increase in sulfur content from 30% to 40% without additive did not result in a change of the PG. However, the addition of crumb rubber to the sulfur/asphalt samples increased PG, which in turn increased the temperature range of applications.

(23) FIG. 1 represents typical complex modulus (G*) versus temperature (T) plot for 30% sulfur and 1%-6% rubber modifed binder. FIG. 1 indicates that a 30/70 sulfur asphalt binder had lower G* values as compared to base asphalt. However, the addition of crumb rubber to 30% by weight sulfur modified asphalt increased its complex modulus significantly.

(24) Table 3 shows the values of complex modulus for 30% and 40% sulfur modified binder with 0%-6% rubber content for three different temperature levels. The values showed that increased rubber content increased the complex modulus of the modified binder. Additionally, the percentage increase in G* is higher at higher temperature, indicating that rubber increased the temperature resistance of the modified binder.

(25) TABLE-US-00003 TABLE 3 Complex Modulus of 30% and 40% Sulfur Binder for Different Rubber Concentrations Complex Complex Complex modulus, Percentage modulus, Percentage modulus, Percentage G* (Pa) @ increase in G* (Pa) @ increase in G* (Pa) @ increase in Sample # Sample compositions 67 C. G* 73 C. G* 79 C. G* 1 Pure Asphalt 1121.51 563.29 295.11 2 30% Sulfur, 70% Asphalt 718.67 35.92 398.74 29.21 243.08 17.63 3 1% Rubber, 30% Sulfur, 2225.52 72.88 1452.36 131.57 848.50 162.56 69% Asphalt 4 2% Rubber, 30% Sulfur, 3056.92 137.47 1886.56 200.81 1021.30 216.03 68% Asphalt 5 4% Rubber, 30% Sulfur, 3850.00 199.07 2390.43 281.15 1273.07 293.94 66% Asphalt 6 6% Rubber, 30% Sulfur, 6290.02 388.62 3625.21 478.03 1899.08 487.65 64% Asphalt 7 40% Sulfur, 60% Asphalt 968.47 13.65 630.60 11.95 419.12 42.02 8 1% Rubber, 40% Sulfur, 1606.41 24.79 955.71 52.39 628.75 94.56 59% Asphalt 9 2% Rubber, 40% Sulfur, 1852.46 43.90 1017.68 62.27 542.01 67.72 58% Asphalt 10 4% Rubber, 40% Sulfur, 2244.69 74.37 1313.37 109.41 876.54 171.24 56% Asphalt 11 6% Rubber, 40% Sulfur, 2626.82 104.06 1596.02 154.48 1080.70 234.41 54% Asphalt

(26) The Marshall Stability values of the samples were calculated in accordance with ASTM D6927. Three samples for each of the designed compositions were tested to obtain an average stability value in kilonewtons (kN). The results showed that pure asphalt concrete compositions had the highest stability value at 20.38 kN. Increases in the sulfur content of the compositions decreased the stability of the compositions in general. All other compositions had stability values ranging from 15 kN to 20 kN. Increased sulfur content of the compositions generally decreased the stability of the compositions. The reason for the decrease in stability with sulfur content can be due to the free sulfur content of the compositions. The unbounded sulfur in the compositions will lead to a softening of the composition through water penetration during the two hours of conditioning in a water bath at 60 C. However, this decrease in stability was minimized through crumb rubber modification. The results of stability and designed compositions are shown in Table 4.

(27) The resilient modulus (M.sub.R) is an important variable for the mechanistic design approaches to pavemented structures. It is the measure of pavement response in terms of dynamic stresses and corresponding resulting strains. The resilient modulus of hot mix asphalt (HMA) was assessed by applying diametral pulse loads to the samples. The load was applied in the vertical diametrical plane of a cylindrical specimen of 63.5-mm (height) by 101.6-mm (diameter). The samples were prepared using the Superpave compaction method. The resulting horizontal deformation of the specimens was measured and used to calculate the resilient modulus. The test was performed at 25 C. The pure asphalt concrete composition had the lowest M.sub.R value, while the sulfur modified asphalt concrete had improved resilient modulus compared to the other compositions. The modified compositions were stiffer than the plain compositions. The addition of sulfur resulted in increased stiffness and the addition of rubber increased the elasticity of the compositions, which increased the resilience of the compositions to dynamic loads as a result of the improvement in the binder elastic properties. The results are shown in Table 4.

(28) The Indirect Tensile Strength (ITS) test (AASHTO T-245) was used to explore composition resistance to cracks development utilizing ITS. The ITS test was performed on cylindrical specimens of 63.5-mm height by 101.6-mm diameter. Samples were prepared for dry and wet ITS testing following exposure to the Superpave compaction method. The maximum load the specimen would carry before failure was determined (known as the ITS). The test was carried out at 25 C. for dry ITS specimens. Three samples were conditioned in a water bath at 60 C. for 24 hours and then put into a water bath at 25 C. for 2 hours. The samples were then tested for wet ITS. The durability was calculated using the ratio of the ITS of the conditioned specimen to the ITS of the unconditioned specimen. The results of the ITS test and durability are shown in Table 4.

(29) Three compositions were selected for rutting (AASHTO TP 63-06) and fatigue resistance (AASHTO T321) testing. The rutting resistance of the selected samples was evaluated using the asphalt pavement analyzer (APA) at 64 C. The wheel load was set to 45.5 kg (100 lb.), and the wheel pressure was set to 689.5 kPa (100 psi), and there were 8000 load repetitions. 150 mm test samples were compacted using a gyratory compactor to the required density of 2550 to 2700 kg/m.sup.3. The test samples were conditioned at the test temperature for 4 hours.

(30) The results indicated that modified compositions had less rutting as compared to the pure asphalt concrete composition.

(31) TABLE-US-00004 TABLE 4 Wet Crumb Stability M.sub.R Dry ITS, ITS, Rutting Sample Sulfur % Asphalt % rubber % KN PG MPa kPa kPa Durability, % mm 1 100 0 20.38 64-10 5342.50 1260.93 769.44 61.02 6.23 2 20 76 4 19.13 70-10 7200.83 1434.02 1097.85 76.56 3.82 3 20 74 6 18.36 70-10 7341.75 1552.43 983.76 63.37 4 30 66 4 17.95 76-10 8129.50 1402.11 936.86 66.82 4.68 5 30 64 6 18.03 76-10 8635.33 1783.85 993.32 55.72 6 40 59 1 17.47 76-10 8547.42 1389.49 1157.31 83.29 7 40 58 2 16.18 76-10 6500.75 1315.23 869.95 66.14 8 50 49 1 17.06 76-10 11161.67 1462.93 1163.21 79.51 9 50 48 2 16.42 76-10 7526.42 1248.50 1041.48 83.41 10 50 46 4 15.67 82-10 7710.67 1443.66 483.03 33.46

(32) TABLE-US-00005 TABLE 5 Examples Sulfur % Asphalt % Rubber % PG 1 0 100 0 64-10 2 30 70 0 64-10 3 40 60 0 64-10 4 20 76 4 70-10 5 30 66 4 76-10 6 40 56 4 76-10 7 50 46 4 82-10

(33) An additional PG test was performed on seven additional samples according to the same parameters as the results in Table 2. The results of this additional test showed that a higher sulfur content in the binder required a smaller percentage of crumb rubber to achieve the same PG grade, as detailed in Table 5. The findings detailed in Table 5 are surprising and unexpected.

(34) In summary, the crumb rubber sulfur asphalt compositions increased the M.sub.R compared to that of asphalt alone, increased the ITS of the compositions compared to that of asphalt alone, and increased the rutting resistance of the compositions as compared to that of asphalt alone.

(35) Although the present invention has been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereupon without departing from the principle and scope of the invention. Accordingly, the scope of the present invention should be determined by the following claims and their appropriate legal equivalents.

(36) The singular forms a, an and the include plural referents, unless the context clearly dictates otherwise.

(37) Optional or optionally means that the subsequently described event or circumstances may or may not occur. The description includes instances where the event or circumstance occurs and instances where it does not occur.

(38) Ranges may be expressed herein as from about one particular value, and/or to about another particular value. When such a range is expressed, it is to be understood that another embodiment is from the one particular value and/or to the other particular value, along with all combinations within said range.

(39) As used herein and in the appended claims, the words comprise, has, and include and all grammatical variations thereof are each intended to have an open, non-limiting meaning that does not exclude additional elements or steps.

(40) As used herein, terms such as first and second are arbitrarily assigned and are merely intended to differentiate between two or more components of an apparatus. It is to be understood that the words first and second serve no other purpose and are not part of the name or description of the component, nor do they necessarily define a relative location or position of the component. Furthermore, it is to be understood that that the mere use of the term first and second does not require that there be any third component, although that possibility is contemplated under the scope of the present invention.