SYSTEMS, MIXTURES AND METHODS OF PRODUCING PAVING PRODUCTS USING SAME

Abstract

A mixture formed from desired proportions of recycled asphalt shingle and recycled asphalt pavement is disclosed. The methods of molding the mixture into paving blocks, which exhibit properties of high compressive strength and low water absorption, are described. The paving blocks may be used to construct roads, parking lots, driveways, etc. A heated auger system for transferring the mixture to a molding system. The heated auger system can include concentric bodies to form separate concentric chambers, with one chamber receiving a heated fluid therethrough, and the other chamber for transporting the mixture through the auger system for heating by the heated fluid.

Claims

1. A method of manufacturing one or more paving blocks using a mixture, the method comprising the following steps: (a) mixing recycled asphalt shingle particles and recycled asphalt pavement particles to produce a homogenous mixture thereof; (b) heating the homogenous mixture of step (a) to a temperature from 200 degrees F. to 425 degrees F. to form a heated mixture; (c) distributing the heated mixture into a molding system; and (d) applying pressure using the molding system to form the paving blocks.

2. The method of claim 1, wherein the pressure in step (d) is at or above 800 pounds per square inch.

3. The method of claim 1, further comprising a step of mixing rock-like material that is not recycled asphalt pavement in with the recycled asphalt shingle particles and recycled asphalt pavement particles to produce the homogenous mixture in step (a).

4. The method of claim 1, further comprising a step of placing hard surfacing material into the molding system prior to step (c).

5. The method of claim 1, wherein the heating of the homogenous mixture in step (b) is conducted in a transfer device that performs step (c).

6. The method of claim 5, wherein the transfer device is an auger system configured to heat the mixture traveling therethrough.

7. The method of claim 6, wherein the auger system comprising: an inner body defining an inner chamber configured to receive the homogenous mixture of step (a) and transport the homogenous mixture to the molding system; and an outer body outwardly concentric with the inner body, the outer body defining an outer chamber configured to heat the homogenous mixture traveling through the inner chamber.

8. The method of claim 7, wherein the auger system further includes an auger rotatably received in the inner chamber and configured to advance the homogenous mixture along a longitudinal length of the auger system.

9. The method of claim 7, wherein the auger system further comprising one or more vents extending through the outer chamber to fluidly communicate the inner chamber with an outside of the outer body.

10. The method of claim 7, wherein the outer chamber is configured to receive a heated fluid to heat the homogenous mixture traveling through the inner chamber.

11. The method of claim 10, wherein the outer chamber further comprising a helical baffle located between the outer body and the inner body, the helical baffle is configured to circulate the heated fluid as it travels through the outer chamber.

12. The method of claim 7, wherein the outer chamber is separated into a first outer chamber and a second outer chamber, wherein the first outer chamber receives a first heated fluid at a first temperature, and the second outer chamber receives a second heated fluid at a second temperature greater than the first temperature.

13. The method of claim 1, further comprising the step of distributing the heated mixture into compartments of the molding system.

14. The method of claim 1, wherein the molding system includes an actuator configured to move the paving blocks out from the molding system.

15. The method of claim 1, wherein the molding system is an extruder configured to produce a continuous paving block, and further comprising the step of cutting the continuous paving block into the paving blocks.

16. A method of manufacturing one or more paving blocks using a mixture, the method comprising the following steps: (a) mixing recycled asphalt shingle particles and recycled asphalt pavement particles to produce a homogenous mixture thereof; (b) transferring the homogenous mixture of step (a) to a molding system using a heated auger and heating the homogenous mixture to a temperature from 200 degrees F. to 425 degrees F. while traveling through the heated auger; and (c) applying pressure using the molding system to form the paving blocks.

17. The method of claim 16, wherein step (b) is conducted utilizing an auger system comprising: an inner body defining an inner chamber configured to receive the homogenous mixture of step (a) and transport the homogenous mixture to the molding system; an outer body outwardly concentric with the inner body, the outer body defining an outer chamber configured to heat the homogenous mixture traveling through the inner chamber; and an auger rotatably received in the inner chamber and configured to advance the homogenous mixture along a longitudinal length of the auger system.

18. The method of claim 17, wherein the auger system further comprising one or more vents extending through the outer chamber to fluidly communicate the inner chamber with an outside of the outer body.

19. The method of claim 17, wherein the outer chamber is configured to receive a heated fluid to heat the homogenous mixture traveling through the inner chamber.

20. The method of claim 19, wherein the outer chamber further comprising a helical baffle located between the outer body and the inner body, the helical baffle is configured to circulate the heated fluid as it travels through the outer chamber.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0107] Subject matter is particularly pointed out and distinctly claimed in the concluding portion of the specification. The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are, therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through the use of the accompanying drawings, in which:

[0108] FIG. 1 is a schematic diagram of a first process used to produce the molded paving block of the present technology;

[0109] FIG. 2 is a schematic diagram of a second process used to produce the molded paving block of the present technology;

[0110] FIG. 3 is a schematic diagram of a third process used to produce the molded paving block of the present technology; and

[0111] FIG. 4 is a schematic diagram of a fourth process used to produce the molded paving block of the present technology.

[0112] FIG. 5 is a schematic diagram of a fifth process used to produce the molded paving block of the present technology;

[0113] FIG. 6 is a schematic diagram of a sixth process used to produce the molded paving block of the present technology;

[0114] FIG. 7 is a perspective view of the auger system of the present technology;

[0115] FIG. 8 is a cross-sectional view of the auger system taken along line 8 in FIG. 7;

[0116] FIG. 9 is a cross-sectional view of the auger system taken along line 9 in FIG. 8;

[0117] FIG. 10 is a cross-sectional view of the alternate embodiment auger system including a first stage outer chamber and a second stage outer chamber;

[0118] FIG. 11 is a schematic diagram showing a second heating section downstream of the auger system.

[0119] The same reference numerals refer to the same parts throughout the various figures.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE PRESENT TECHNOLOGY

[0120] While the known methods and devices fulfill their respective, particular objectives and requirements, the aforementioned devices or systems do not describe mixtures and methods that allows for producing paving products from recycled asphalt shingles (RAS) and recycled asphalt pavement (RAP) particles.

[0121] A need exists for a new and novel mixtures and methods that can be used for producing paving products from recycled asphalt shingles (RAS) and recycled asphalt pavement (RAP) particles. In this regard, the present technology substantially fulfills this need. In this respect, the mixtures and methods according to the present technology substantially departs from the conventional concepts and designs of the prior art, and in doing so provides an apparatus primarily developed for the purpose of producing paving products from recycled asphalt shingles (RAS) and recycled asphalt pavement (RAP) particles.

[0122] In the following description, for purposes of explanation and not limitation, specific details are set forth, such as particular embodiments, procedures, techniques, etc. in order to provide a thorough understanding of the present technology. However, it will be apparent to one skilled in the art that the present technology may be practiced in other embodiments that depart from these specific details.

[0123] The following description sets forth various examples along with specific details to provide a thorough understanding of claimed subject matter. It will be understood by those skilled in the art, however, that claimed subject matter may be practiced without one or more of the specific details disclosed herein. Further, in some circumstances, well-known methods, procedures, systems, components and/or circuits have not been described in detail in order to avoid unnecessarily obscuring claimed subject matter. In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and make part of this disclosure.

[0124] Reference will now be made to FIG. 1, which provides a schematic representation of a first process used to form the composite paving block of the present technology. At the start of production line 100, there are three metered load hoppers, 101, 102 and 103. The hopper 101 being for RAS, 102 for RAP, and 103 for rock-like material that is not RAP. The RAS, RAP, and rock-like material that is not RAP are loaded into their respective hoppers with a machine such as a front-end loader or a skid steer. The RAS, RAP, and rock-like material that is not RAP are metered proportionally by mass from hoppers 101, 102, and 103 onto conveyor 114 below the hoppers. Conveyor 114 conveys the RAS, RAP, and rock-like material that is not RAP to pug mill 110. Conveyor 114 deposits the RAS, RAP, and rock-like material that is not RAP into pug mill infeed hopper 106, through which the RAS, RAP, and rock-like material that is not RAP pass to pug mill mix augers 115. Pug mill mix augers 115 blend the RAS, RAP, and rock-like material that is not RAP together into the composite material, which is then discharged through pug mill metered discharge hopper 107. There is a fourth metered load hopper 104, which is for the hard surface material. Metered load hopper 104 is loaded with a machine such as a front-end loader or a skid steer, and it discharges through chute 124 directly into preform press 140. If hard surface material is being used, then preform press mold 142 is loaded first with the hard surface material, which is metered proportionally by mass from hopper 104 onto chute 124 and from there slides into preform press mold 142; but if hard surface material is not being used then this step is skipped. The composite material is metered proportionally by mass from hopper 107 onto chute 127 and, from there, slides into preform press mold 142 of preform press 140. Preform press ram 141 applies pressure to the material in preform press mold 142 to effect compaction of the material into a preform. Preform press ram 141 is then raised to remove pressure on the preform, and preform press floor 143 is moved out of the way by the actuator to allow preform press ram 141 to press the preform down onto conveyor 117 below. Conveyor 117 conveys the preform through continuous feed oven 118, where it is heated to about 400 degrees F. and then deposits the heated preform onto chute 129. The heated preform slides down chute 129 into mold press 160. Mold press side door 161 is opened by the actuator to allow the heated preform to enter mold press mold 163. Mold press side door 161 is closed by the actuator and mold press ram 164 applies pressure to the heated preform in mold press mold 163 to effect compaction of the heated preform into a molded paving block. Mold press ram 164 is then raised to remove pressure on the molded paving block, and mold press floor 162 is moved out of the way by the actuator to allow mold press ram 164 to press the molded paving block down onto conveyor 119 below. Conveyor 119 conveys the molded paving block some distance for cooling.

[0125] Reference will now be made to FIG. 2, which provides a schematic representation of a second process used to form the composite paving block of the present technology. At the start of production line 200, there are three metered load hoppers, 101, 102, and 103. The hopper 101 is for RAS, 102 for RAP, and 103 for rock-like material that is not RAP. The RAS, RAP, and rock-like material that is not RAP are loaded into their respective hoppers with a machine such as a front-end loader or a skid steer. The RAS, RAP, and rock-like material that is not RAP are metered proportionally by mass from hoppers 101, 102, and 103 onto conveyor 114 below the hoppers. Conveyor 114 conveys the RAS, RAP, and rock-like material that is not RAP to pug mill 110. Conveyor 114 deposits the RAS, RAP, and rock-like material that is not RAP into pug mill infeed hopper 106, through which the RAS, RAP, and rock-like material that is not RAP pass to pug mill mix augers 115. Pug mill mix augers 115 blend the RAS, RAP, and rock-like material that is not RAP together into the composite material, which is then discharged through pug mill metered discharge hopper 107. The composite material is metered proportionally by mass from hopper 107 into heated auger 116 below. Heated auger 116 heats the composite material to about 400 degrees F. as it draws it toward chute 128. There is a fourth metered load hopper 105, which is for the hard surface material. Metered load hopper 105 is loaded with a machine such as a front-end loader or a skid steer. If hard surface material is being used, then mold press mold 163 is loaded first with the hard surface material, which is metered proportionally by mass from hopper 105 onto chute 125 and from there slides into mold press mold 163; but if hard surface material is not being used then this step is skipped. Heated auger 116 deposits the heated composite material onto chute 128, and the heated composite material slides down chute 128 into mold press 160. Mold press ram 164 applies pressure to the material in mold press mold 163 to effect the compaction of the material into a molded paving block. Mold press ram 164 is then raised to remove pressure on the molded paving block, and mold press floor 162 is moved out of the way by the actuator to allow mold press ram 164 to press the molded paving block down onto conveyor 119 below. Conveyor 119 conveys the molded paving block some distance for cooling.

[0126] Reference will now be made to FIG. 3, which provides a schematic representation of a third and preferred process used to form the composite paving block of the present technology. At the start of production line 300, there are four temperature-controlled metered load hoppers, 101, 102, 103, and 104, with the hopper 101 being for RAS, 102 for RAP, 103 for rock-like material that is not RAP and 104 for hard surface material. The four materials are loaded into their respective hoppers with a machine such as a front-end loader or a skid steer. The four hoppers are heated with temperature control to maintain temperatures around the following for each of the four materials: RAS 100 degrees F.; RAP 140 degrees F.; rock-like material that is not RAP 1200 degrees F.; and hard surface material 450 degrees F. Press 140 is heated with temperature control to maintain its temperature around 400 degrees F. The materials are metered proportionally by mass from their hoppers via a chute into press mold 142. If hard surface material is being used, then press mold 142 is loaded first with the hard surface material, which is metered proportionally by mass from hopper 104 onto chute 124 and from there slides into press mold 142; but if hard surface material is not being used then this step is skipped. The RAS, RAP, and rock-like material that is not RAP are metered proportionally by mass from hoppers 101,102 and 103, respectively, onto chutes 121, 122, and 123, respectively, and from there slide into press mold 142 of press 140. The RAS, RAP, and rock-like material that is not RAP are loaded intermittently so that many layers of RAS are interspersed with many layers of RAP and many layers of rock-like material that is not RAP until press mold 142 is filled to the desired level. The mixture of materials with varying temperatures results in a blended temperature of around 400 degrees F. Press ram 141 applies pressure to the material in press mold 142 to effect the compaction of the material into a molded paving block. Press ram 141 is then raised to remove pressure on the molded paving block, and press floor 143 is moved out of the way by the actuator to allow press ram 141 to press the molded paving block down onto conveyor 119 below. Conveyor 119 conveys the molded paving block some distance for cooling.

[0127] Reference will now be made to FIG. 4, which provides a schematic representation of a fourth process used to form the composite paving block of the present technology. At the start of production line 400, there are four metered load hoppers, 101, 102, 103, and 104, with hopper 101 being for RAS, 102 for RAP, 103 for rock-like material that is not RAP, and 104 for hard surface material. The four materials are loaded into their respective hoppers with a machine such as a front-end loader or a skid steer. The materials are metered proportionally by mass from their hoppers via a chute into preform press mold 142. If hard surface material is being used, then preform press mold 142 is loaded first with the hard surface material, which is metered proportionally by mass from hopper 104 onto chute 124 and from there slides into preform press mold 142; but if hard surface material is not being used then this step is skipped. The RAS, RAP, and rock-like material that is not RAP are metered proportionally by mass from hoppers 101,102 and 103, respectively, onto chutes 121, 122, and 123, respectively, and from there slide into preform press mold 142 of preform press 140. The RAS, RAP, and rock-like material that is not RAP are loaded intermittently so that many layers of RAS are interspersed with many layers of RAP and many layers of rock-like material that is not RAP until the preform press mold is filled to the desired level. Preform press ram 141 applies pressure to the material in preform press mold 142 to effect compaction of the material into a preform. Preform press ram 141 is then raised to remove pressure on the preform, and preform press floor 143 is moved out of the way by the actuator to allow preform press ram 141 to press the preform down onto conveyor 117 below. Conveyor 117 conveys the preform through continuous feed oven 118, where it is heated to about 400 degrees F. and then deposits the heated preform onto chute 129. Mold press side door 161 is opened by the actuator to allow the heated preform to enter mold press mold 163. The heated preform slides down chute 129 into mold press 160. Mold press side door 161 is closed by the actuator, and mold press ram 164 applies pressure to the heated preform in mold press mold 163 to effect compaction of the heated preform into a molded paving block. Mold press ram 164 is then raised to remove pressure on the molded paving block, and mold press floor 162 is moved out of the way by the actuator to allow mold press ram 164 to press the molded paving block down onto conveyor 119 below. Conveyor 119 conveys the molded paving block some distance for cooling.

[0128] Reference will now be made to FIG. 5, which provides a schematic representation of a fifth process used to form a composite paving block 10 of the present technology. At the start of production line 500, there are three metered load hoppers, 101, 102, and 103. The hopper 101 is for RAS, 102 for RAP, and 103 for rock-like material that is not RAP. The RAS, RAP, and rock-like material that is not RAP are loaded into their respective hoppers with a machine such as a front-end loader or a skid steer. The RAS, RAP, and rock-like material that is not RAP are metered proportionally by mass from hoppers 101, 102, and 103 onto conveyor 114 below the hoppers. Conveyor 114 conveys the RAS, RAP, and rock-like material that is not RAP to a pug mill 502. Conveyor 114 deposits the RAS, RAP, and rock-like material that is not RAP into pug mill infeed hopper 504, through which the RAS, RAP, and rock-like material that is not RAP pass to pug mill mix augers or blades 506. In one or more embodiments, the conveyor 114 can be individual chutes associated with each of the hoppers 101, 102, and 103, that are configured to deposit the metered RAS, RAP, and rock-like material that is not RAP into the pug mill infeed hopper 504.

[0129] Pug mill mix augers or blades 506 blend the RAS, RAP, and rock-like material that is not RAP together into the composite material, which can then be discharged through pug mill metered discharge hopper 508. The composite material is metered proportionally by mass from hopper 508 into heated auger 116 below. Heated auger 116 heats the composite material to about 400 degrees F. as it draws it toward chute 128.

[0130] In some embodiments, the hopper 508 can be omitted and the auger 116 can receive the composite material directly or can be integrally associated with a bottom section of the pug mill 502.

[0131] The heated auger 116 deposits the heated composite material onto chute 128, while a mold press ram 516 is in a raised position, and the heated composite material slides down chute 128 into a mold press 510. Mold press ram 516 applies pressure to the material in mold press mold 512 to effect the compaction of the material into a molded paving block 10. An actuator 514 located near a bottom of the mold press mold 512 is operated to push the molded paving block 10 out from the mold press mold 512 and onto a conveyor 119. The actuator 514 can be operated while the mold press ram 516 is in the raised or lowered position. Conveyor 119 conveys the molded paving block 10 some distance for cooling.

[0132] In some embodiments, the mold press 510 can include the mold press floor 162 and actuator in place of the actuator 514 to move the mold press floor 162 out of the way to allow mold press ram 516 to press the molded paving block 10 down onto conveyor 119 below.

[0133] In one or more embodiments, there can be a fourth metered load hopper 105, which is for the hard surface material. Metered load hopper 105 is loaded with a machine such as a front-end loader or a skid steer. If hard surface material is being used, then mold press mold 512 is loaded first with the hard surface material, which is metered proportionally by mass from hopper 105 onto chute 125 and from there slides into mold press mold 512, then the material is deposited into the mold press mold 512 by chute 128 so the material is on top of the hard surface material.

[0134] Reference will now be made to FIG. 6, which provides a schematic representation of a sixth process used to form a composite paving block 10 of the present technology. At the start of production line 600, there are three metered load hoppers, 101, 102, and 103. The hopper 101 is for RAS, 102 for RAP, and 103 for rock-like material that is not RAP. The RAS, RAP, and rock-like material that is not RAP are loaded into their respective hoppers with a machine such as a front-end loader or a skid steer. The RAS, RAP, and rock-like material that is not RAP are metered proportionally by mass from hoppers 101, 102, and 103 onto conveyor 114 below the hoppers. Conveyor 114 conveys the RAS, RAP, and rock-like material that is not RAP to a pug mill 502. Conveyor 114 deposits the RAS, RAP, and rock-like material that is not RAP into pug mill infeed hopper 504, through which the RAS, RAP, and rock-like material that is not RAP pass to pug mill mix augers or blades 506. In one or more embodiments, the conveyor 114 can be individual chutes associated with each of the hoppers 101, 102, and 103, that are configured to deposit the metered RAS, RAP, and rock-like material that is not RAP into the pug mill infeed hopper 504.

[0135] Pug mill mix augers or blades 506 blend the RAS, RAP, and rock-like material that is not RAP together into the composite material, which can then be discharged through pug mill metered discharge hopper 508. The composite material is metered proportionally by mass from hopper 508 into heated auger 116 below. Heated auger 116 heats the composite material to about 400 degrees F. as it draws it toward chute 128.

[0136] The heated auger 116 transfers the heated composite material to an extruder 602 that compresses the composite material and forces it through an extruder die 604 having a paving block shape. The extruder 602 creates a continuous flow of the composite material through the extruder die 604 to form a continuous paving block 12 that exits the extruder 602 and onto to a conveyor 119. The extruder die 604 can be removable and interchangeable with other dies of different configurations, allowing different continuous paving blocks 12 to be formed.

[0137] A slicing or cutting mechanism 606 can be utilized with the extruder die 604 or the conveyor 119 to cut the continuous paving block 12 into separate paving blocks 10. Conveyor 119 conveys the cut paving blocks 10 some distance for cooling.

[0138] Referring to FIGS. 7-9, in some embodiments the heated auger 116 can include an outer cylindrical body 620 defining an outer chamber 622, and an inner cylindrical body 632 defining an inner chamber 634. The heated auger 116 can be a jacketed auger system allowing for a heated fluid to pass through the outer chamber 622, thereby heating the composite material traveling through the inner chamber 634. It can be appreciated that the inner cylindrical boy 632 is concentric with the outer cylindrical body 620 along a longitudinal length of the auger 116. Further, the outer cylindrical body 620 can be capped or sealed at both its ends and with the inner cylindrical body 632 to contain the heated fluid in the outer chamber 622.

[0139] A spiral or helical baffle 624 can be located in the outer chamber 622 allow for optimal heat transfer from the heated fluid traveling through the outer chamber 622 to the inner chamber 634.

[0140] A heater 650 can be utilized to heat the fluid in a controllable manner, and to circulate the fluid to and from the outer chamber 622. It can be appreciated that the heater 650 includes any and all appropriate components to provide heat to the fluid, to receive the fluid, to output the fluid and to circulate the fluid. The heater 650 can include a computer control system, along with any required sensors and/or communication components.

[0141] The heated fluid can be, but is not limited to, an oil, water or any liquid capable of transferring heat to the inner chamber 634. In some embodiments, an oil can be used as the heated fluid as it has a delta T (T) than other heating systems such as a furnace burning natural gas. The greater delta T of the furnace may overheat the composite material traveling through the auger 116, and this overheating can release volatiles which is required for binding of the composite material during the pressing process in making the paver block. Accordingly, the use the heater 650 to controllably heat the oil allows for an optimum heat transfer to the composite material traveling through the inner chamber 634, while not overheating the composite material and thereby retaining the volatiles in the composite material for assisting in the binding processes.

[0142] In some embodiments, other mechanisms to heat the inner chamber 634 can be utilized in place of or in combination with the heated fluid such as, but not limited to, recovered flue exhaust gas, a furnace, geothermal, solar, an electrical heater, electromagnetic heating, radio-frequency (RF) heating, and the like.

[0143] An input 626 can be associated with a discharge end of the outer cylindrical body 620 for providing the heated fluid from the heater 650 to the outer chamber 622. An output 628 can be associated with a receiving end of the outer cylindrical body 620 for exiting the now cooler heated fluid from the outer chamber 622 for transfer back to the heater 650.

[0144] A receiving and output section of the heater 650 that receives the cooled heated fluid from and outputs the heated fluid to the outer cylindrical body 620 can be at a height greater than a height of the input 626 and the output 628. This elevated height of the heater 650 can be utilized to control a level of the fluid, to remove any air in the fluid, and/or to prevent flooding of the heater 650.

[0145] One or more vents 630 can pass through the outer cylindrical body 620, through the outer chamber 622, and through the inner cylindrical body 632 so as to be in communication with the inner chamber 634. The vents 630 can be configured to allow steam or other gases to escape the inner chamber 632, which may have been released from the composite material heated by the heated fluid. The vents 630 can include a screen, mesh or collection system for filtering and/or capturing the escaping steam and/or gases.

[0146] An auger device 636 is rotatably received in the inner chamber 634, and in the exemplary can be operatively associated with a gear/pulley 638 that can be driven by a chain, belt or gear 640, which be driven by a motor 642.

[0147] The pug mill 502 or any other mixing hopper can be positioned near the receiving end of the outer cylindrical body 620 to deliver the mixed composite material into the inner chamber 632 for transfer therethrough by the auger device 636.

[0148] A discharge nozzle or fitting 642 can be removably attached to the discharge end of the outer cylindrical body 620. This can be accomplished by a flange 644 that can be fastened to the discharge end. The discharge fitting 642 including a hollow interior in communication with the inner chamber 634, and configured to receive the heated composite material exiting the inner chamber 634 and the auger device 636. The discharge fitting 642 can be configured to guide the exiting heated composite material into any one of or any combination of the preform press 140, the mold press 160, the mold press 510, and the extruder 602.

[0149] The auger 116 can be supported on a base 654 by one or more support arms 656, thereby making the auger 116 transportable.

[0150] Referring to FIG. 10, in some embodiments the auger 116 can be an alternate auger 116 having a first stage heating section and a second stage heating section. The first stage heating section can include the outer chamber 622 defining the first stage heating section, the helical baffle 624 and its corresponding input 626, output 628 and vents 630. The input 626 can be located near a discharge end of the first stage heating section, and can be configured to receive a first heated fluid at a first temperature suitable to remove moisture and/or steam from the composite material at a first stage location of the inner chamber 634 adjacent the first stage heating section. The temperature of the first heated fluid can be, but not limited to, 176 degrees F. (80 degrees C.) to 248 degrees F. (120 degrees C.). While the second stage heating section can receive a second heated fluid at a temperature greater than the first heated fluid to increase the temperature of the composite material to sufficient operating temperature while containing volatiles. The temperature of the second heated fluid can be, but not limited to, 248 degrees F. (120 degrees C.) to 374 degrees F. (190 degrees C.).

[0151] The output 628 can be associated with the receiving end of the outer cylindrical body 620 for exiting the now cooler first heated fluid from the outer chamber 622 for transfer back to the heater 650.

[0152] The second stage heating section can be between the first stage heating section and the discharge end of the outer cylindrical body 620 including the discharge fitting 642. The second stage heating section can be defined by a baffle or stop wall 650 located between the outer cylindrical body 620 and the inner cylindrical body 632, thereby sealing and separating the outer chamber 622 and a second stage outer chamber 652 of the second stage heating section.

[0153] A second stage input 656 can be associated with the discharge end of the outer cylindrical body 620 that defines the second stage outer chamber 652 for providing the second heated fluid from the heater 650 to the second stage outer chamber 652. A second stage output 654 can be associated with an end of the second stage outer chamber 652 adjacent to the stop wall 650 for exiting the now cooler second heated fluid from the second stage outer chamber 652 for transfer back to the heater 650.

[0154] A second stage helical baffle 654 can be utilized in the second stage outer chamber 652 to provide optimum heat transfer of the second heated fluid to the composite material flowing past the second stage heating section of the alternate auger 116.

[0155] The heater 650 can be configured to separately and independently heat the first and second fluids, and to provide separate and independent circulation of the first and second fluids to and from their corresponding outer chambers 622, 652.

[0156] Referring to FIG. 11, an alternative second stage heating section is illustrated and will be described. A second heating section 662 can be associated with the discharge fitting 642 or an additional conduit connected to the discharge fitting 642. The second heating section 662 can be, but not limited to, a jacketing fluid heating assembly similar in operation to the above described auger 116. A second stage outer chamber 664 can be defined outwardly concentric with a second stage inner chamber 666 that is configured to receive the heated composite material from the auger 116. A second heated fluid is received in the second stage outer chamber 664 utilizing a second stage input 668, wherein the second heated fluid travels through the second stage outer chamber 664 to heat the received heated composite material to a temperature greater than the temperature of the heated composite material exiting the auger 116. A second stage output 670 can be associated with an end of the second stage outer chamber 664 opposite to that of the second stage input 668 for exiting the now cooler second heated fluid from the second stage outer chamber 664 for transfer back to the heater 650.

[0157] A second discharge nozzle or fitting 672 can be removably attached to the discharge end of the second heating section 660. The second discharge fitting 672 can include a hollow interior in communication with the second stage inner chamber 666, and configured to receive the heated composite material exiting the second stage inner chamber 666 and the auger device 636. The second discharge fitting 672 can be configured to guide the exiting heated composite material into any one of or any combination of the preform press 140, the mold press 160, the mold press 510, and the extruder 602.

[0158] In some embodiments, the extruder 602 and the auger 636 can be combined into a single unit. The auger 636 section can include an end section that has an auger blade compressing section that is configured to compress the heated composite material against the discharge end. The discharge fitting 642 can include or can be replaced with an extruder die. In operation, a first section of the auger 636 can be configured to transfer the composite material through the heated section of the auger system 116. While a compressing section of the auger 636 can be configured to increasingly compress the heated composite material at or above 800 pounds per square inch, while still transfer it toward the discharge end and thus against the extruder die. The compressed and heated composite material would then be pressed against the extruder die for shaping the composited material into a desired continuous shaped paving block, which can then be cut into preferred length blocks.

[0159] In some embodiments, the RAP material of the present technology can be or can include sand tailings, which is a byproduct from oil sands extraction processa byproduct of separating bitumen from clay, sand and silt using high volumes of water and chemicals. Sand tailings can be a mixture of water, sand, fine silts, clay, residual bitumen and lighter hydrocarbons, inorganic salts and water-soluble organic compounds. Tailings are typically stored in basins called tailings ponds, which allow the solids in tailings to settle, or they can be recovered from ponds and piled. The present technology can first dry the sand tailings RAP to a moisture content of no more than 10%, and preferable no more than 5%. In some embodiments, already dried sand tailings can be obtained and processed into RAP with subsequent drying if required. Then the sand tailings RAP can be added to the mill or mixing hopper prior to entry into the heated auger. The use of sand tailings as RAP solves an ecological problem associated with tailing ponds and large piles of sand tailings that release hazardous chemicals into the atmosphere and/or into surrounding bodies of water. The bitumen content of the sand tailings RAP could also increase the binding properties of the composite material when pressed into the paving blocks.

[0160] With regard to all of the processes shown, although the drawings show only a single compartment in the molding systems depicted, all of the molding systems may comprise a single compartment or multiple compartments; and likewise with the support apparatus for each molding system.

[0161] With regard to certain of the processes shown, there are various ways of loading the heated preform from the continuous feed oven into the mold press, including, among others, manual loading, loading via the robotic arm, and loading via mechanically guided dropping. Mold press side door 161 and chute 129 are shown for simplicity.

[0162] With regard to certain of the processes shown, the heated preform should be appreciably shorter and thinner than mold press mold 163 so as to ease loading into mold press mold 163.

[0163] With regard to all processes shown, it is possible to preheat the RAS and RAP prior to depositing them into hoppers 101 and 102, respectively. Working with the RAS while it is below the temperature of 100 degrees F. and RAP while it is below the temperature of 140 degrees F. is advantageous for two reasons. The first reason is that these materials do not adhere badly to the equipment when they are below these temperatures, whereas they do adhere once they are warmed above these temperatures. Such adherence causes ongoing maintenance issues with the equipment, including the need for frequent cleaning and the need to shutdown to clear out components to avoid the risk of them requiring intensive de-gumming. The other reason is that heating RAS and RAP releases volatile organic compounds from any heated surface area. The release of these volatile organic compounds causes noxious odors that must be controlled and also reduces the binder quality of the asphalt cement in the RAS and RAP. So keeping the RAS and RAP below these threshold temperatures prior to the molding of the preform, at which point the surface area of the RAS and RAP is minimized to the surface area of the preform, is far better than heating the RAS and RAP appreciably prior to molding the preform.

[0164] With regard to certain of the processes shown, although a pug mill is shown as the blending device, there are many other adequate types of blending devices that can be used instead of a pug mill.

[0165] With regard to all processes shown, the RAS, RAP, and rock-like material that is not RAP have preferably been screened such that all pieces are of a size under 1 in any dimension.

[0166] With regard to all processes shown, the hard surface material has preferably been screened such that all pieces are of a size under in any dimension.

[0167] With regard to all processes shown, it has been found that a temperature of about 250 degrees F. to about 425 degrees F., and particularly a temperature of about 350 degrees F. to about 400 degrees F., is useful in providing the proper heat for producing a molded paving block with the desired level of compressive strength and resistance to water absorption.

[0168] With regard to all processes shown, the proportional mix of RAS and RAP is important. The RAP (or rock-like material that is not RAP) provides the compressive strength and abrasion resistance of the composite material, whereas the RAS provides most of its cleavage strength and resistance to water absorption. The two together make a far superior paver than could be made with either alone. However, in an instance where the objective is to use as much RAS as possible, the proportion of RAP can be reduced. Although such RAP reduction could be taken even to the point of elimination, the loss of compressive strength becomes significant enough that the molded paving blocks produced would be unsuitable for anything other than walking paths. If the RAS component exceeds 50% then the compressive strength is essentially provided by the binder, and the aggregate is superfluous.

[0169] With regard to all processes shown, although rock-like material that is not RAP can replace RAP entirely, there is good reason to use some portion of RAP. This is because RAP is already coated with asphalt cement, whereas rock-like material that is not RAP is not coated with asphalt cement; this results in the RAS binding more easily with RAP than with rock-like material that is not RAP. When rock-like material that is not RAP is used, the asphalt cement in the RAS is absorbed to a greater degree into the rock-like material that is not RAP, thus requiring one or more of a higher percentage of RAS, higher pressure, or more dwell time in the oven.

[0170] It is contemplated that any embodiment discussed in this specification can be implemented with respect to any method of the present technology, and vice versa. It will be also understood that particular embodiments described herein are shown by way of illustration and not as limitations of the present technology. The principal features of this present technology can be employed in various embodiments without departing from the scope of the present technology. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this present technology and are covered by the claims.

[0171] All publications and patent applications mentioned in the specification are indicative of the level of skill of those skilled in the art to which this present technology pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference. Incorporation by reference is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein, no claims included in the documents are incorporated by reference herein, and any definitions provided in the documents are not incorporated by reference herein unless expressly included herein.

[0172] The use of the word a or an when used in conjunction with the term comprising in the claims and/or the specification may mean one, but it is also consistent with the meaning of one or more, at least one, and one or more than one. The use of the term or in the claims is used to mean and/or unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and and/or. Throughout this application, the term about is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.

[0173] As used in this specification and claim(s), the words comprising (and any form of comprising, such as comprise and comprises), having (and any form of having, such as have and has), including (and any form of including, such as includes and include) or containing (and any form of containing, such as contains and contain) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps. In embodiments of any of the compositions and methods provided herein, comprising may be replaced with consisting essentially of or consisting of. As used herein, the phrase consisting essentially of requires the specified integer(s) or steps as well as those that do not materially affect the character or function of the claimed present technology. As used herein, the term consisting is used to indicate the presence of the recited integer (e.g., a feature, an element, a characteristic, a property, a method/process step or a limitation) or group of integers (e.g., feature(s), element(s), characteristic(s), properties(s), method/process steps or limitation(s)) only.

[0174] The term or combinations thereof as used herein refers to all permutations and combinations of the listed items preceding the term. For example, A, B, C, or combinations thereof is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, AB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context.

[0175] As used herein, words of approximation such as, without limitation, about, substantial or substantially refers to a condition that when so modified is understood to not necessarily be absolute or perfect but would be considered close enough to those of ordinary skill in the art to warrant designating the condition as being present. The extent to which the description may vary will depend on how great a change can be instituted and still have one of ordinary skilled in the art recognize the modified feature as still having the required characteristics and capabilities of the unmodified feature. In general, but subject to the preceding discussion, a numerical value herein that is modified by a word of approximation such as about may vary from the stated value by at least 1, 2, 3, 4, 5, 6, 7, 10, 12, 15, 20 or 25%.

[0176] All of the devices and/or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the devices and methods of this present technology have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the devices and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the present technology. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the present technology as defined by the appended claims.