Phosphated compounds as adhesion promoters

Abstract

A bitumen containing composition, comprising bitumen and a phosphate compound, which is obtainable by the esterification of a polyhydric alcohol having at least three hydroxyl groups, with a carboxylic acid having 8-24 carbon atoms, preferably 12-22 carbon atoms, or a derivative thereof, wherein at least one but not all of the hydroxyl groups are esterified, provided that when the polyhydric alcohol has 5 or more hydroxyl groups then at least two but not all of the hydroxyl groups are esterified, followed by reacting the ester obtained with a phosphatising reagent; wherein the said composition is not a bitumen-in-water emulsion.

Claims

1. A bitumen containing composition comprising bitumen and a phosphate compound, the phosphate compound prepared by the esterification of a polyhydric alcohol having at least three hydroxyl groups, with a carboxylic acid having 8-24 carbon atoms, or a derivative thereof, wherein at least one but not all of the hydroxyl groups are esterified, provided that when the polyhydric alcohol has 5 or more hydroxyl groups, then at least two but not all of the hydroxyl groups are esterified, followed by reacting the ester obtained with a phosphatising reagent; wherein the said composition is not a bitumen-in-water emulsion.

2. The composition according to claim 1, wherein the phosphated compound has the formula: ##STR00006## where Z=PO.sub.3H, H or R(CO), where R(CO) is an acyl group having 8-24 carbon atoms; and n=0-3; provided that at least one Z is R(CO) and at least one Z is PO.sub.3H, provided that when n=2 or 3 then at least two Z is R(CO); or the formula: ##STR00007## where X=CH.sub.2OZ or CH.sub.2CH.sub.3; Z has the same meaning as in formula I; and ##STR00008## provided that at least one Z is PO.sub.3H and at least one Z is R(CO).

3. The composition according to claim 2, wherein in formula (I), n=0.

4. The composition according to claim 2, wherein in formula (I), n=3.

5. The composition according to claim 2, wherein in formula (II), X is CH.sub.2OZ and Y is Z.

6. The composition according to claim 2, wherein in formula (II), X is CH.sub.2CH.sub.3 and ##STR00009##

7. The composition according to claim 3, wherein said phosphate compound is prepared by the steps of transesterification of a triglyceride with glycerol, followed by reaction with a phosphatising reagent.

8. The composition according to claim 1, further comprising less than 5 wt % water.

9. The composition according to claim 8, wherein the phosphate compound is 0.05 to 5% by weight, based on the amount of bitumen.

10. A method for strengthening adhesion between bitumen and aggregates comprising the step of: adding the bitumen containing composition of claim 1 to the said aggregates.

11. An asphalt composition comprising the bitumen containing composition of claim 1 and aggregates.

12. The asphalt composition according to claim 11, comprising from 1 to 25% by weight of the bitumen, and 75 to 99% by weight of the aggregates.

13. A method for paving a road, a sidewalk, a parking lot or an airport runway comprising the step of: applying the asphalt composition of claim 11 to a road surface, a sidewalk surface, parking lot surface, or an airport runway surface.

14. The method according to claim 13, wherein the paying method is a hot-mix or warm-mix paving procedure.

15. A method for paving comprising the steps of: mixing the bitumen composition of claim 1 with aggregates to form a mixture having a temperature of 100-190 C.; and applying said mixture to a surface.

16. The bitumen containing composition of claim 1, wherein the carboxylic acid has 12-22 carbon atoms.

17. A method for strengthening adhesion between bitumen and aggregates comprising the step of: adding the phosphated compound of claim 1 to the aggregates to form a phosphate compound-aggregate mixture, and thereafter adding the bitumen to the phosphated compound-aggregate mixture.

18. The method of claim 15, further comprising the step of compacting said mixture after it was applied to the surface.

19. A bitumen containing composition comprising bitumen and a phosphate compound, the phosphate compound prepared by the esterification of a polyhydric alcohol having at least three hydroxyl groups, with a carboxylic acid having 8-24 carbon atoms, or a derivative thereof, wherein at least one but not all of the hydroxyl groups are esterified, provided that when the polyhydric alcohol has 5 or more hydroxyl groups, then at least two but not all of the hydroxyl groups are esterified, followed by reacting the ester obtained with a phosphatising reagent, and wherein the phosphated compound has the formula: ##STR00010## where Z=PO.sub.3H, H or R(CO), where R(CO) is an acyl group having 8-24 carbon atoms; and n=0-3; provided that at least one Z is R(CO) and at least one Z is PO.sub.3H, provided that when n=2 or 3 then at least two Z is R(CO); or the formula: ##STR00011## where X=CH.sub.2OZ or CH.sub.2CH.sub.3; Z has the same meaning as in formula I; and ##STR00012## provided that at least one Z is PO.sub.3H and at least one Z is R(CO), and further wherein where n=0 in formula (I), the phosphate compound is prepared by the steps of transesterification of a triglyceride with glycerol, followed by reaction with a phosphatising reagent, and further wherein the composition comprises less than 5 wt % water, and further wherein bitumen is present in an amount of greater than 90 wt %.

Description

DETAILED DESCRIPTION OF THE INVENTION

(1) A first aspect of the present invention relates to a bitumen containing composition comprising bitumen and a phosphated compound, which is obtainable by the esterification of a polyhydric alcohol having at least three hydroxyl groups, with a carboxylic acid having from 8, preferably from 12, to 24, preferably to 22 carbon atoms, or a derivative thereof, wherein at least one but not all of the hydroxyl groups are esterified, provided that when the polyhydric alcohol has 5 or more hydroxyl groups then at least two but not all of the hydroxyl groups are esterified, followed by reacting the ester obtained with a phosphatising reagent; wherein said composition is not a bitumen-in-water emulsion.

(2) In a first embodiment the phosphated compound has the formula

(3) ##STR00001##
where Z=PO.sub.3H, H or R(CO), where R(CO) is an acyl group having from 8, preferably from 12, to 24, preferably to 22 carbon atoms; and n=0-3; provided that at least one Z is R(CO) and at least one Z is PO.sub.3H, provided that when n=2 or 3 then at least two Z is R(CO).

(4) In a second embodiment the phosphated compound has the formula

(5) ##STR00002##
where X=CH.sub.2OZ or CH.sub.2CH.sub.3; Z has the same meaning as in formula I; and

(6) ##STR00003##
provided that at least one Z is PO.sub.3H and at least one Z is R(CO).

(7) Suitable polyhydric alcohols to be used as starting materials for products of formula (I) are glycerol, erythritol, threitol, arabitol, xylitol, ribitol, mannitol, sorbitol and galactitol, preferably glycerol.

(8) The carboxylic acids to be used as starting materials for products of formula (I) and (II) may be linear or branched, preferably linear, substituted or unsubstituted, preferably unsubstituted, and saturated or unsaturated, preferably unsaturated. Suitable examples of these acids are for example lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, palmitoleic acid, oleic acid, gadoleic acid, erucic acid, ricinoleic acid, linoleic acid, linolenic acid, arachidonic acid, and the so-called natural fatty acids, such as coco fatty acid, tallow fatty acid, rape seed fatty acid, soya fatty acid, and tall oil fatty acid (TOFA),

(9) Suitable phosphatising agents include polyphosphoric acid (PPA) and diphosphorous pentoxide (P.sub.2O.sub.5).

(10) For the compound of formula (I) there is a specific embodiment where n=0, at least one and preferably at least two of the Z groups are R(CO) and the remaining Z groups or group is PO.sub.3H. These compounds are known as phospholipids, and may be prepared by methods known in the art (see e.g. GB 1,032,465, DE 24 46 151, U.S. Pat. Nos. 3,875,196 and 2,177,983 for synthesis descriptions). A preferred structure is formed by esterification of 1.5-2 mol of fatty acid with 1 mol of glycerol, followed by reaction of the obtained intermediate with polyphosphoric acid (PPA) or diphosphorus pentoxide (P.sub.2O.sub.5).

(11) Alternatively, the compound of formula (I) where n=0 can be obtained by transesterification of an oil or fat (triglyceride) with glycerol, typically in a molar ratio triglyceride:glycerol of about 2:1, and typically in the presence of base (eg. KOH), followed by reaction of the obtained intermediate with PPA or P.sub.2O.sub.5. The products obtained by the above-mentioned methods are normally mixtures of phosphated mono- and diglycerides, where the main product is a phosphated diglyceride. The product mixture may also contain triglycerides and minor amounts of mono-, di- and triphosphated glycerol.

(12) Also other polyhydric alcohols may be esterified with a carboxylic acid and thereafter phosphated. Another specific embodiment is based on sorbitol (n=3), where the product has the formula

(13) ##STR00004##
where Z=PO.sub.3H, H or R(CO), provided at least two Z is R(CO), and at least one Z is PO.sub.3H.

(14) A specific embodiment of the compound of formula (II) is where X is CH.sub.2OZ and Y is Z, where at least one, preferably at least two Z is R(CO), and at least one Z is PO.sub.3H. The starting polyhydric alcohol in this case is pentaerythritol.

(15) Two further specific embodiments of the compound (II) are where X is CH.sub.2CH.sub.3 and

(16) ##STR00005##
where the starting polyhydric alcohol is trimethylolpropane or di-trimethylolpropane, respectively.

(17) The derivatives that may be used in the esterification reaction instead of the carboxylic acid itself are e.g. an acid chloride, an ester or an anhydride thereof.

(18) The phosphated compounds of the invention having formula (I) are especially preferred, since they have a particularly good environmental profile and a good thermal stability. The most preferred compounds of formula (I) are those where n=0.

(19) The bitumen containing composition comprising bitumen and a phosphated compound as defined above, preferably a compound having formula (I) or (II), more preferably formula (I), and most preferably a compound having formula (I) in which n is 0, preferably comprises >90 wt % bitumen and <5 wt % water.

(20) The amount of the phosphated compound to be added to the bitumen containing composition is preferably at least 0.05, more preferably at least 0.1, even more preferably at least 0.2, and most preferably at least 0.3% by weight, and preferably at most 5, more preferably at most 4, even more preferably at most 3 and most preferably at most 2% by weight, based on the amount of bitumen.

(21) The compound of formula (I) or (II) significantly increases the adhesion of bitumen towards both acidic aggregates, such as granite, and alkaline aggregates, such as limestone. A second aspect of the invention is thus a method for strengthening the adhesion between bitumen and aggregates by adding the said bitumen containing composition to the said aggregates, or by first adding the phosphated compound as defined above to the aggregates and thereafter adding the bitumen to the phosphate compound-aggregate mixture.

(22) A third aspect of the invention is an asphalt composition comprising bitumen, a phosphated compound as defined above, preferably a compound having formula (I) or (II), more preferably formula (I), and most preferably a compound of formula (I) where n=0, and aggregates.

(23) The amount of the bitumen containing composition in the final asphalt composition is preferably 1 to 25% by weight, more preferably 2 to 15% by weight and most preferably 3 to 10% by weight of the final composition. The amount of aggregates in the final asphalt composition is preferably 75 to 99% by weight of the final composition.

(24) Bitumen (in North America also referred to as asphalt) is one of the heavier, if not the heaviest, portions from the oil distillation process. Due to the different origins and distillation processes of such oils, the resulting bitumen may have a wide range of properties and characteristics.

(25) Binder is herein defined as bitumen or bitumen including additives, such as the phosphated compounds described herein.

(26) As used in the present invention the term asphalt refers to a composition comprising binder and aggregates.

(27) As used in the present invention, the term bitumen refers not only to the product from oil by direct distillation or from distillation of oil at reduced pressures, but also to the product resulting from the extraction of tar and bituminous sands, the product of oxidation and/or fluxation of such bituminous materials, as well as blown or semi-blown bitumens, synthetic bitumens (such as described in FR 2 853 647-A1), tars, oil resins or indene-coumarone resins mixed with aromatic and/or paraffinic hydrocarbons, chemically modified bitumen, such as polymer modified bitumen and/or acid modified bitumen, and mixtures thereof.

(28) So-called cut-back bitumen, i.e. bitumen diluted with a petroleum solvent, such as e.g. naphtha, kerosene and/or diesel to lower its viscosity, is also within the definition of bitumen as used herein. However, preferred bitumen for use in the present invention comprises at most 5 wt %, preferably at most 4 wt % of petroleum solvents, such as naphtha, kerosene and/or diesel.

(29) The adhesion promoter of the present invention is thus not restricted to be used with any specific kind of bitumen.

(30) Normally the adhesion promoting phosphated compound of the invention would be added to the bitumen, and this mixture thereafter added to the aggregates. Alternatively the phosphated compound could first be added to the aggregates and thereafter the bitumen added to the phosphated compound-aggregate mixture.

(31) The asphalt comprising the additive of the invention could be used in different paving methods, such as with hot mixes, warm mixes, soft bitumen mixes and foamed bitumen, preferably with hot mixes. It may be used for paving a road, a sidewalk, a parking lot or an airport runway. It may also be used in asphalt roofing applications, sealants and coatings, such as roofing shingles and driveway sealers.

(32) A suitable method for paving comprises the steps of mixing the bitumen composition as defined above with aggregates to form a mixture having a temperature of 100-190 C. applying said mixture to a surface optionally compacting said mixture.

(33) The above method is preferably a conventional hot-mix or warm-mix paving method.

(34) Bitumen may comprise minor amounts of water dispersed therein. Preferably, bitumen contemplated for use in the present invention comprises less than 5, preferably less than 4, and most preferably less than 1 wt % water, and is typically essentially anhydrous.

(35) As used herein, the term aggregate relates to divided materials from quarries, stone material, bituminous mix aggregates, such as from reclaimed asphalt, milled fragments, clinker, scoria, slag and concrete.

(36) The mean size of the aggregates is typically less than 5, preferably less than 3 cm in any dimension, and typically has a mean size of at least 0.1 cm, preferably at least 0.3 cm in at least one dimension. It is however to be recognized that the aggregates often comprises a portion of filler particles, which are finely divided materials having a particle size of below 75 m.

(37) The aggregates used could be either acidic or basic. Acidic aggregates include those with high silica contents, while basic aggregates include carbonates. Non-limiting examples of suitable aggregates are limestone, sandstone, granite and diabase.

(38) Hot-mix asphalt (HMA) is produced by mixing heated bitumen and heated, dried aggregates in the right proportions to obtain the product mixture that is desired. The production temperature is generally 120-190 C., typically 150-180 C., and depends on the bitumen that is used. A proper aggregate temperature is essential, since it is mainly the temperature of the aggregate that controls the temperature of the asphalt mixture. Warm-mix asphalt (WMA) is a variation of traditional HMA, using processes or additives to HMA that allow mixture production and placement to occur at temperatures lower than conventional HMA without sacrificing performance. To make the WMA process possible, technologies including chemical binder additives, chemical mixture additives, foaming admixtures and plant modifications may be used. The process temperature for a WMA is roughly between 100 and 140 C., which is typically 20-40 C. lower than for an equivalent HMA, i.e. as for a HMA having the same type of bitumen and aggregates. In the HMA and WMA the bitumen is not in the form of an emulsion.

(39) The asphalt composition may further comprise minor amounts of other additives commonly used in the art.

(40) The invention is further illustrated by the working examples below.

EXPERIMENTAL

Example 1

(41) Synthesis of Phospholipids (I)

(42) TABLE-US-00001 TABLE 1 The amount of the reagents used for the reaction and specifications on raw materials Molar n, Mw, ratio mol g/mol m, g Reagent 1.80 1.28 282.8 361.98 Sylfat 2 (ex Arizona Chemical).sup.1 1.00 0.713 92.09 65.7 Glycerol 1.00 0.713 142 101.2 Polyphosphoric acid (PPA) .sup.1Tall Oil Fatty Acid (TO-2)
Procedure

(43) TO-2 and glycerol were added to a round bottom flask equipped with a thermometer, a heating mantle, distillation set up, a nitrogen/vacuum inlet and a mechanical stirrer. The reaction mixture was heated up to 165 C. and the reaction water was distilled off. The distillation was carried out under vacuum (30 mbar) at 165 C. for approximately 13 hours. The progress of the reaction was evaluated by determination of acid value and by .sup.1H NMR, and the conversion was around 90%.

(44) Polyphosphoric acid was added to the reaction mixture using a dropping funnel, keeping the temperature between 57 and 64 C. The post reaction was carried out at 65 C. and atmospheric pressure under vigorous mixing for approximately 3 hours. 471 g of the product was collected.

Example 2

(45) Synthesis of Oleyl Phosphate (OleylPPA; Comparison Product)

(46) TABLE-US-00002 TABLE 1 The amount of the reagents used for the reaction and specifications on raw materials Molar n, Mw, ratio mol g/mol m, g Reagent 1.00 0.767 268 205.6 Synative AL 90/95 V (ex Cognis).sup.2 1.00 0.767 142 108.9 Polyphosphoric acid (PPA) .sup.2Oleyl/Cetyl alcohol, based on vegetable raw material (linear, mainly unsaturated alcohol)
Procedure

(47) Synative AL 90/95 V was added to a round bottom flask equipped with a thermometer, a nitrogen inlet, a heating mantle, a mechanical stirrer and a dropping funnel. The reagent was heated to 65 C. under stirring. Polyphosphoric acid was added in portions to the flask with a dropping funnel during 30 min. keeping the temperature between 54 and 74 C. The reaction mixture was then heated at 70 C. for 1 h. 297.3 g of the product was collected. The product was evaluated by .sup.1H-NMR spectroscopy.

Example 3

(48) Synthesis of Oleyl Phosphate.sup.3 (OleylP2O5; Comparison Product)

(49) TABLE-US-00003 TABLE 2 The amount of the reagents used for the reaction and specifications on raw materials Molar n, Mw, ratio mol g/mol m, g Reagent 1.00 0.94 277 260 Synative AL 90/95 V (ex Cognis) 0.39 0.37 142 53.2 Phosphorous pentoxide (P.sub.2O.sub.5) .sup.3This product contains about equal amounts of mono- and dialkyl phosphate
Procedure

(50) Synative AL 90/95 V was added to a round bottom flask equipped with a thermometer, a nitrogen inlet, a heating mantle, a mechanical stirrer and a funnel. The reagent was heated to 45 C. under stirring. Phosphorous pentoxide (39.9 g) was added to the flask in portions during 1 h, keeping the temperature between 45 and 68 C. An additional portion of P.sub.2O.sub.5 (13.3 g) was added and the reaction was heated for 5 h at 65 C. 302.5 g of the product was collected.

(51) The final product was evaluated by .sup.1H-NMR and .sup.31P-NMR.

Example 4

(52) General Method for Determination of Adhesion

(53) This method was designed to test the passive adhesion (water sensibility) between an aggregate and a binder. It can also be used to test the effect of an adhesion agent.

(54) Dried and cleaned aggregates (8.0-11.2 mm) were covered with a binder (3.5% by weight). The covered aggregates were transferred to a bottle, which was filled with water and placed in a warm water-bath.

(55) Observations were made after 24 hours and the percentage of stone surface that remained coated was noted.

(56) Procedure

(57) Aggregates, Granite (acidic) and Diabase (alkaline) were sieved to 8.0-11.2 mm, thoroughly washed, rinsed with deionized/distilled water and dried at 150 C. for 5 hours. 230 g aggregate was prepared in a mixing vessel and the mixing vessels with aggregate was placed in an oven set at mixing temperature (165 C.) 2 hours before mixing. Bitumen (Shell, Pen 70/100) was weighed out in 150 ml closed tin cans, each containing 500.2 g. The tin cans with the bitumen were put into an oven set at mixing temperature (165 C.) about 3 hours before mixing.

(58) The adhesion promoter was weighed into the warm bitumen 3010 minutes before mixing with the aggregate. The adhesion promoter and the bitumen were thoroughly mixed by means of a spatula for 30 seconds.

(59) The adhesion promoters were added to the bitumen in the following amounts:

(60) TABLE-US-00004 Adhesion Dosage Dosage (%) Bitumen Total Promoter (g) of total (g) (g) OleylPPA 0.256 0.508 50.20 50.458 (Comparison) OleylP2O5 0.256 0.507 50.18 50.436 (Comparison) Phospholipids (I) 0.258 0.511 50.20 50.456 No additive 50.15 50.15 (Comparison)
Procedure

(61) Aggregates and binder were prepared as described above.

(62) To a mixing vessel with aggregates (230 g, 165 C.) the binder (with or without adhesion promoter) (80.1 gram, 165 C.) was added. Mixing started within 305 sec after the aggregates and the binder had been taken out of the oven. Mixing was done with a spatula for one minute at a rate of about 3 revolutions per second whereupon the aggregates were totally covered with binder.

(63) The coated aggregates were immediately put into a glass bottle and left at room temperature to cool over night.

(64) The water-bath temperature was held at 60 C. approximately 3 hours before the transfer of the coated aggregate to the bottles. The bottles with aggregate-binder were filled with deionized/distilled water and placed in the water-bath at 60 C. for 24 hours.

(65) After 24 hours of immersion, the state of the coated aggregates in water was visually inspected. By this inspection, the area percentage of the aggregates coated by the binder was estimated.

(66) TABLE-US-00005 Adhesion promoter Granite Diabase Phospholipid (I) 95 95 OleylPPA (Comparison) 80 95 OleylP.sub.2O.sub.5 (Comparison) 60 85 No additive (Comparison) 10 75