RU2525487C1 - Method and device for making modified rubber-bitumen putties - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: method includes heating of bitumen to temperature of 90-120°C in a heat insulated reservoir (1), addition of rubber crumb and polyethylene. Besides, rubber crumb is added into the reservoir into bitumen in the amount of 10-20 wt % and mixed, and polyethylene is added into the additional heat insulated tight reservoir (14) in the amount of 1-2 wt % and poured with a self-flowing mixture of bitumen and rubber crumb. Then the produced mix is heated to temperature 130-170°C, and with the help of a gear pump (23) they perform multiple recirculation of the mix via the heat insulated reservoir. The device for preparation of putty comprises the heat insulated reservoir (1) with a heating device (2), a neck (3) and a mixing device (35), a mixing drive (42), a stop valve (12), a drain manifold (11) and pipelines. Besides, between the stop valve (12) and the neck (3) below the reservoir level (1) there is a tight heat insulated additional reservoir (14) with the second heating device (19), to the outlet of the reservoir (14) a recirculation pipeline (25) is connected, as well as a gear pump (23) with a drive (34), the outlet of the pipeline (25) is connected with the neck (3) of the reservoir (1).

EFFECT: reduced cost of putty in case of increased quality and durability of a roof putty coating.

14 cl, 9 dwg, 3 tbl

Description

The group of inventions relates to construction equipment and can be used to repair the roof by pouring it with hot rubber-bitumen mastic. The use of mastic for repairing the roof roof allows avoiding seams, an unreasonable number of joints, irregularities, and the use of a mastic roof allows you to get a seamless roofing membrane over the entire area of the reconstructed roof section. The installation for the preparation of modified rubber-bitumen mastics produces mastics made of bitumen, in which substances are added to combat brittleness, to increase the softening temperature of high molecular weight chemical compounds consisting of homogeneous repeating groups of atoms, which ensures increased durability of the roof being repaired.

Roof repair

Roof repair is a necessity that sooner or later every homeowner faces. There is no doubt that this part of the building must be strong, airtight and reliable. The roof serves as a house protection not only from atmospheric precipitation, but also from excessive heat loss.

The roof of the roofing material must be coated with bitumen mastic. A new roof requires such a grease only after five years, and the subsequent grease depends on the degree of wear of the roof. For lubrication, liquid mastics, heated and cold, are sometimes used. The range of such mastics is quite wide.

Roof coating should start from the highest place and gradually go down. If necessary, too dry roofing can be smeared twice and sprinkled with sand on top. If there are bubbles in such a roof, they need to be cut crosswise, unscrew the edges and remove the mastic from the base. Then you need to cover the place with fresh mastic, attach a piece of roofing paper under the turned edges, grease again and glue the cut corners. If a patch is applied, it should also be coated with mastic. According to the parameters, the patch must go beyond the seams, and at least 10 cm.

The backlog of the roll roof can be eliminated as follows: cut only along the roof ridge and stick its lower part to the base. Then you need to cut a strip of roofing tape (20-30 cm wide and in accordance with the cut part length). Mastic should be applied from top to bottom on the base and bottom of the roofing roof and from bottom to top on the top. A strip of roofing paper is inserted into the hole. In order to eliminate the holes in the roll roof, they must be sealed with patches from roofing pieces. The base is lubricated with mastic. If there are too many holes, the roll roof should be cleaned, a fresh coat of mastic applied and a new coat of roofing laid. Laying is best done in the direction of the slope of the roof so that the edges of the pieces are overlapped. Firmly press the layer to the base to avoid bubbles. Roofing is attached to the edge of the roof with steel strips, so that the coating does not break even in strong winds.

A known method of making mastic according to the patent for the invention of the Russian Federation No. 20144374, IPC E01C 19/08, publ. June 15, 1994

The inventive device comprises a container with heat pipes, a heat exchanger from concentrically arranged pipes, one of which is communicated through a pipe with a bitumen supply pipe from the storage in the lower part, and one of its pipelines to the container in the upper part. The other pipe of the heat exchanger is in communication with the pipeline for supplying and discharging the coolant, in the cavity of the pipe for the coolant are arranged in tiers and the pipe elements crosswise pointwise contact their surfaces along the axis of the heat exchanger. Their open ends are fixed on the outer surface of the pipe for the coolant. Its outer diameter is 0.65-0.85 of the outer diameter of the pipe for bitumen. The outer diameter of each tubular element is 0.3-0.5 of the outer diameter of the pipe for the coolant. The device may have a water outlet pipe with a three-way tap and a glass at the bottom of the bitumen pipe. Its bottom is attached to the lower end of the coolant pipe. The edge of the downward facing glass is serrated and is located in the lower part of the bitumen pipe at the outlet to the pipe for water drainage. The bitumen feed pipe is fixed on the side surface of the bitumen pipe above the bottom of the glass, the outer diameter of which is 0.93-0.96 of the inner diameter of the pipe for the coolant. The coolant supply pipes are coaxially located outside and inside the bitumen supply pipe. The outer diameter of the bitumen supply pipeline is 0.55-0.75 of the outer diameter of the outer pipe for the coolant, the outer diameter of the coolant pipe is 0.45-0.65 of the outer diameter of the bitumen.

The disadvantage is the complexity of the design.

A known method of preparing mastic according to the patent of the Russian Federation for the invention No. 201475, IPC E01C 19/08, publ. June 15, 1994

The device contains a container with heat pipes, a steam separator, an evaporator, pipelines for transferring and discharging bitumen with valves. The edge of the glass is fixed to the lower end of the pipe for the bitumen of the heat exchanger. The water outlet pipe is fixed on the side surface of the glass. The outer diameter of the pipe for the coolant is 0.30-0.45 of the outer diameter of the pipe for bitumen and 0.80-0.90 of the inner diameter of the glass. The outer diameter of the bitumen feed pipe is 0.15-0.25 of the outer diameter of the bitumen pipe. The bitumen supply pipe from the storage can be located above the glass. The bitumen discharge pipe may be located at the top of the heat exchanger pipe.

Disadvantages - design complexity and negative impact on the environment.

A known method of preparing mastic according to the patent of the Russian Federation for the invention No. 2062828, IPC E01C 19/08, publ. 06/27/1996

The proposed device contains a container with a lid, electric heating elements with protective heat-conducting shells horizontally located above the bottom of the container, the current-carrying leads of which are located in niches with caps on opposite walls of the container, an automatic process control system. Vertical rods are connected to the ends of the electric heating elements located near the walls of the tank by means of clamps. Their upper parts are located above the level of the material and are connected to the inner surface of the walls of the tank by means of pads. The crane is made in the form of a sleeve coaxially placed in the drain pipe with a handle and a pin fixed at one end. The pin is located in a groove made in the drain pipe with the possibility of restricting the angle of rotation of the sleeve by 90 °. The other end end of the sleeve is blind and has longitudinal grooves. The axis of the drain pipe is located at an acute angle to the horizontal plane of the bottom in the area of the heating elements. The grooves of the sleeve and the holes of the drain pipe are aligned and made equal.

The disadvantage is the poor uniformity of the composition of the mastic due to the lack of a mixing device.

A known method of making mastic according to the patent of the Russian Federation for the invention No. 2158244, IPC С04В 26/26, C08L 95/00, publ. 10/27/2000

The invention relates to a method for producing mastic for the device of roofless roofs of buildings, as well as for waterproofing building structures. A method of producing an asbestos-bitumen emulsion is to obtain a suspension of asbestos in water with moderate stirring, dispersing the molten bitumen in water in a Garth intensive mixer or colloid mill to obtain bitumen particles less than 0.15 mm in the presence of an emulsifier and then stirring the asbestos suspension and dispersed bitumen with moderate stirring to obtain a finished emulsion of the following ratio: bitumen: asbestos: emulsifier = 1: 0.85-2: 0.005-0.16 and their total concentration in the emulsion 40-56.8%. The emulsifier is selected from the group: a mixture of asbestos with finely ground calcium oxide in a ratio of 0.24-0.3: 0.08-0.12, sodium alkylaryl sulfonate, a mixture of sodium polymethylene naphthalene sulfonates with sodium lignosulfonate, sodium or potassium salts of tall oil acids, ethoxylated fatty alcohols C ₈ -C ₁₈ with a degree of hydroxyethylation of 8-12. EFFECT: increased tensile strength, water tightness during operation with a sufficiently high rate of moisture removal during drying in natural conditions.

The disadvantage is the high cost of energy.

A known method of making mastic according to the patent of the Russian Federation No. 2160293, IPC C08L 95/00, C08L 23/22, C09D 195/00, C09B 123/22, publ. 12/10/2000

The composition of the waterproofing mastic, wt.%: A mixture of cracked visbreaking residue and tar of Arlan oil in a ratio of 1: 4 45-55, butyl rubber 11-12, a mixture of selective purification of the third oil fraction and deasphalting agent in a ratio of 1: 1 7.5-8 , 0, liquid styrene-butadiene rubber 2.5-3.0, sludge from the production of sulfonate additives 3.6-4.6, solvent 20-30.4. The invention solves the technical problem of improving the operational properties of the composition at low temperature.

Disadvantage: the mastic is not intended for application to the roof, but is intended mainly as an anti-corrosion coating for metal.

A known method of preparing mastic according to the patent of the Russian Federation for the invention No. 2182867, IPC B29B 7/14, publ. May 27, 2002

The invention can be used in construction for the production of bitumen-roofing material from previously dismantled, crushed layers of the old bitumen-roofing material and suitable for the construction of the roof. The installation comprises an inlet device for supplying the starting components and a mixing chamber mounted obliquely and rotatably. In the chamber there is a mixer in the form of a shaft with ring elements mounted on it. Each annular element consists of two rings, a hub, a pair of wide blades and two pairs of narrow blades, rigidly connected with the hub and rings. The blades are rotated around the axis by an angle that provides optimal conditions for the advancement of bitumen-ruberoid mass along the planes of the blades. Each annular element is rotated along the axis of the shaft, relative to the previous one, to allow the bitumen-ruberoid mass to advance in the direction opposite to the discharge direction by an angle α = 360 ° / n, where n is the number of annular elements. A screw is rigidly attached to the outer surface of the rings.

The disadvantage is that these method and installation do not provide high quality products due to the use of waste.

A known method of preparing mastic according to the patent of the Russian Federation for the invention No. 2177969, IPC C08L 95/00, C08L 9/06, publ. 01/10/2002

The invention relates to the field of producing bitumen-polymer compositions used in road construction for the production of polymer-bitumen binders, in the manufacture of roofing and waterproofing materials, sealants, mastics. In the method for producing a bitumen-polymer composition, 100 parts by weight are mixed. thermoplastic elastomer based on conjugated diene and vinyl aromatic monomer, 70-200 parts by weight bitumen preheated to a temperature of 90-110 ° C, 30-250 wt.h. mineral filler and stirring at a temperature of 70-100 ° C for 10-15 minutes, the resulting mixture is homogenized at a temperature of 130-160 ° C for 10-15 minutes in a screw extruder equipped with a granulating device, cooled with water, having a temperature of 20- 40 ° C, through which the composite mass passes, then the obtained granules of the composition are dried and packaged. At the beginning of mixing, a plasticizer can be added to the composition — industrial or tall oil in the amount of 10-20 parts by weight. per 100 parts by weight specified thermoplastic elastomer.

The disadvantage is that the device is intended only for the preparation of granules. When they are melted, energy is additionally expended and the cost of roofing increases by 2 times.

A known method of preparing mastic according to the patent of the Russian Federation for invention No. 2188835, IPC C08L 95/00, С04В 40/00, С04В 26/26, publ. 09/10/2002

A method of preparing a universal bitumen mastic, including mixing heated bitumen, talc, rubber glue based on natural rubber and white spirit in a mixer in a predetermined range of ratios until a homogeneous mass is formed, consists in first loading heated bitumen into a paddle mixer, into which at a temperature of 100-130 ° C, rubber glue based on natural rubber is introduced and mixed for 10-30 minutes, then talc is added to the mixture, mixed for 10-30 minutes, then white spirit is introduced, the final mixing for no more than 40 min until the temperature of the mixture reaches 70-90 ° C and determine the homogeneity of the mass, and if it does not meet the established requirements, the ratio of the components of the mastic is adjusted in a given interval and additional mixing is performed. The components of the mastic are taken in the ratio, wt.%: Bitumen 57.5-70, rubber glue 2-3.2, talc 2-3, white spirit 24-38.5. EFFECT: increased heat resistance and adhesion to materials, facilitated application process on glued surfaces.

The disadvantage is the use of expensive solvents in large quantities.

A known method of preparing mastic according to the patent of the Russian Federation for the invention No. 2208025, IPC C08L 95/00, publ. 07/10/2003

This invention relates to the production of a polyurethane-bitumen composition intended for the manufacture of a new bulk and repair of an old roof, as well as for waterproofing and anticorrosive protection of various surfaces. The technical task is to increase the elongation at break of the material, improve the strength characteristics of the cured material, as well as reduce its water absorption. This is achieved by the fact that the polyurethane-bitumen composition, consisting of a solution of bitumen, a polyol as one component and an isocyanate component, contains as a polyol and isocyanate components a prepolymer based on a mixture of polyoxypropylene triols with a molecular weight of 250-5000 and toluene diisocyanate in their weight ratio of polyoxypropylene triol: toluene diisocyanate (75 -85) :( 25-15) respectively, as a solution of bitumen it contains bitumen-shale mastic in the following ratio of components, parts by weight: the above solution bitumen 80-90; the above prepolymer 10-20.

The disadvantage is the high cost of the mastic due to the use of expensive components.

A known method of preparing mastic according to the patent of the Russian Federation for the invention No. 2248381, IPC C08L 95/00, C08L 23/16, C08L 9/00, C08K 5/13, publ. March 20, 2005

Bitumen-polymer material and its production method relate to the field of industrial preparation of modified bitumen mastics, sealing and waterproofing materials with improved technical characteristics for use in road and industrial-civil construction. The bitumen-polymer material consists of petroleum bitumen, synthetic rubber, petroleum solvent and / or fuel oil, sulfur-containing compounds and additionally containing, as a surfactant, ethoxylated alkyl phenol, as a sulfur-containing compound contains a sulfonated mixture of petroleum bitumen, synthetic rubber, petroleum solvent and / or fuel oil, treated before sulfonation with air at a temperature of 140-230 ° C, in the following ratio of components, parts by weight: bitumen 60-70; rubber 2-10; sulfonated mixture of petroleum bitumen, synthetic rubber, petroleum solvent and / or fuel oil 0.5-5.0; petroleum solvent and / or fuel oil 18-30; hydroxyethylated alkyl phenol 0.1-5.0. A method for producing the above material is also described. This improves the quality and productivity of obtaining polymer-modified bitumen mastics and sealants for waterproofing, using inexpensive affordable materials with energy savings.

The disadvantage is the high cost of the mastic.

A known method of preparing mastic according to the patent of the Russian Federation for the invention No. 2258074, IPC C08L 75/08, C08L 95/00, publ. 08/10/2005.

The invention relates to the production of a polyurethane-bitumen composition used as sealants, coatings for waterproofing and anticorrosive protection of various surfaces (concrete, metal, etc.). The polyurethane-bitumen composition consists of bitumen-slate mastic and prepolymers based on a mixture of polyoxypropylene triols and an isocyanate component, a mixture of two prepolymers is used as a prepolymer: the first is based on a mixture of polyoxypropylene triols with a molecular weight of 300-6000 and toluene diisocyanate in the ratio (80-85): (20-15) respectively; the second - based on a mixture of polyoxypropylene triols with a molecular weight of 300-6000 and hexamethylene diisocyanate in the ratio (65-80) :( 50-20) when their ratio in the mixture of prepolymers (80-50) :( 50-20) with the following content of the components of the composition, parts by weight: bitumen-slate mastic 70-95, a mixture of prepolymers 5-30. Achieved is an increase in elongation at break of the material, an increase in tensile strength, a decrease in water absorption, a decrease in abrasion, and the ability to control the degree of hardness and elasticity of the coating.

The disadvantage is the high cost of mastic due to the high cost of its components.

A known method of preparing mastic according to the patent of the Russian Federation for the invention No. 2284398, IPC E04D 15/06, publ. 09/27/2006

The invention relates to construction and can be used in the repair of roofs made of bitumen-containing materials, in particular from roofing material. The technical result of the invention is the creation of a reliable set of equipment for the restoration of roofs from bitumen-containing materials. A set of equipment for restoring roofs made of bitumen-containing materials includes a mobile unit located on a restored roof, and a unit separately installed on the ground for processing old roofing material and a unit for preparing mastic for feeding. A mobile installation consists of a drive mechanism and trolley-carts connected to it and with each other with technological equipment installed on them, including a device for cleaning the roof, a device for making vertical channels and a device for heating the roof mounted on a trolley with floating rollers. The mobile installation further comprises a series-connected unit for leveling the roof surface, consisting of a centrifugal fan, a drive milling drum and a device for heating the roof; cyclone for collecting bitumen mass with a pump and a supply hose; a unit for the preparation of mastic, consisting of a mixing chamber, a dispenser, a device for heating the mastic, a pump and a supply hose; a unit for feeding mastic, made of a container with nozzles for direct filling of mastic and for spraying, a pump and a feed hose, mounted on a trolley with ordinary rollers. The devices for heating the old roofing material, roofing and mastic are made of a gas gas generator using liquid fuel or an electric air heater and a guiding casing, and the gas heat generator is made of a metal case with external heat-insulated walls and partitions inside the case forming a preliminary combustion chamber, a combustion chamber, an afterburner, and a gas exhaust path to the guide casing of the fuel-air mixture supply mechanism to the preliminary combustion chamber, consisting of a pipeline for liquid fuel and a centrifugal fan, with its nozzle aligned coaxially in the horizontal section, with adjustable air intake flaps, while the end of the pipe is made bent at right angles to the side of the nozzle of the nozzle and coaxially placed in its body.

The disadvantage is the high cost of equipment.

A known method of preparing mastic according to the patent of the Russian Federation for the invention No. 2299225, IPC C08L 95/00, publ. 05/20/2007

The invention relates to the field of building materials, more specifically to heat and waterproofing materials for the construction and repair of various roofs, in particular gluing rolled bituminous and bitumen-polymer materials to brick, concrete, metal, wood, ceramic and other surfaces, and for mastic waterproofing of building structures, buildings and structures. Bitumen-polymer mastic contains, wt.%: Toluene 48-50; bitumen 19-21; thermoplastic elastomer 12.5-14.5; mineral filler-talc 13-15; resin-rosin 2.5-4.5. A method for producing mastic is described. Effect: simplification of the composition and method of manufacturing mastic with the simultaneous achievement of a combination of mastic with various materials, in particular roofing, when creating a roofing carpet of buildings and structures.

The disadvantage is the high cost of the mastic.

A known method of preparing mastic according to the patent of the Russian Federation for the invention No. 2299226, IPC C08L 95/00, publ. 05/20/2007

The invention relates to the field of building materials, more specifically to heat and waterproofing materials for the construction and repair of various roofs, in particular gluing rolled bituminous and bitumen-polymer materials to brick, concrete, metal, wood, ceramic and other surfaces, and for mastic waterproofing of building structures, buildings and structures. Bitumen-polymer mastic contains, wt.%: Toluene 31-34; bitumen 30.5-37; thermoplastic elastomer 5-11.5; mineral filler-talc 21-23; resin-rosin 2.5-3.5.

The disadvantage is also the high cost of mastic.

A known method of preparing mastic according to the patent of the Russian Federation for invention No. 2323231, IPC C08L 19/00 (2006.01), C08K 5/13 (2006.01), C08K 5/17 (2006.01), publ. 04/27/2008

The invention relates to a rubber-bitumen mastic containing bitumen, crumb rubber, a plasticizer and a filler, characterized in that its composition additionally uses nitrile butadiene rubber (2.5-4.0 wt.%) And maleic anhydride (2.0- 2.5 wt.%), While the liquid fraction of liptobiolite coal tar with a boiling point above 230 ° C (20.0-30.0 wt.%) Was used as a plasticizer, and talc (22.5- 35.0 wt.%), While bitumen makes up the rest of the mastic. The use of these components of the mastic with the stated limits of the contents provides the possibility of obtaining increased values of elasticity, strength of the mastic and its adhesion with the material to be protected, at softening and brittleness temperatures that ensure effective “work” of the mastic in harsh climatic conditions.

Disadvantage: mastic works relatively poorly in hot climatic zones.

A known method of preparing mastic according to the patent of the Russian Federation for the invention No. 2345107, IPC C08L 95/00 (2006.01), publ. 01/27/2009

The invention relates to a polymer-bitumen mastic containing bitumen, styrene-butadiene thermoplastic elastomer, a filler, a solvent, characterized in that the polymer-bitumen mastic further comprises a polar type plasticizer dibutyl phthalate and a petroleum plasticizer PN-bK in the following ratio, wt.%: Bitumen 40.0 -60.0; styrene butadiene thermoplastic elastomer 2.0-14.0; a plasticizer of the polar type dibutyl phthalate 1.0-4.0; oil plasticizer PN-6K 1.0-4.0; filler 1.0-5.0; solvent rest.

The disadvantage is the use of a large number of relatively expensive components.

A known method of preparing mastic according to the patent of the Russian Federation for the invention No. 2045492, IPC C04B 26/26, C08L 95/00, publ. 10/10/1995, the prototype of the method and device.

The inventive method for preparing a bitumen-polymer composition is to melt the bitumen component at 60-180 ° C and the formation of granules enclosed in a shell of a thermoplastic polymer. Before use, the granules are melted and stirred at 160-200 ° C. Moreover, the bitumen component with a temperature of 60-180 ° C is fed by gravity or under pressure into the polymer shell, forming a moving sleeve and granulated. Also, the bitumen component at 60-100 ° C is first granulated and then a polymer melt is applied to the granules and cooled in water or air. As a bitumen component, bitumen is used, a mixture of bitumen with a thermoplastic polymer or its waste in an amount of 1-15% by weight of the bitumen composition, as well as bitumen-polymer, bitumen-asbestos, rubber-bitumen mastics. In addition, the shell of the granules is made of the same polymer that is used in the bitumen component. The method provides the convenience of storage and transportation of the composition, as well as protecting it from moisture and contamination.

But this method has significant disadvantages that affect the cost of repairing the roof upward. Due to the high cost of electricity, the preparation of mastic at relatively high temperatures requires its high costs. In addition, the re-melting of the granules will increase energy costs by another 2 ... 2.5 times and will require the purchase of additional equipment for melting the granules and spill mastic. This will further increase the cost of the mastic.

The objective of the invention is to reduce the cost of mastic while improving the quality and durability of the roofing mastic coating.

The solution of these problems was achieved in the method of preparing a modified rubber-bitumen mastic, including heating bitumen to a temperature of 90 ... 120 ° C in a thermally insulated container, adding rubber crumb and polyethylene, so that according to the invention only rubber crumb in the amount of 10 ... 20 is added to the insulated container in bitumen % of the mass. and they are mixed, and in an additional heat-insulated sealed container pour polyethylene in an amount of 1 ... 2% of the mass. and fill with a mixture of bitumen with rubber crumb supplied by gravity, then the resulting mixture is heated additionally to a temperature of 130 ... 170 ° C and using the gear pump, the mixture is repeatedly recycled through a heat-insulated container. Recycling can be carried out within 1.5 ... 2 hours.

The solution of these problems was achieved in a device for preparing a modified rubber-bitumen mastic, containing a thermally insulated container for heating bitumen with a heating device, a neck and a mixing device, a stirring drive, a gate valve, a drain line and pipelines, so that, according to the invention, between the gate valve and the neck below the level heat-insulated capacity installed sealed heat-insulated additional capacity, with a second heating device, to the exit a recirculation pipeline and a gear pump with a drive are connected from the intermediate tank, the outlet of the recirculation pipeline is connected to the neck of the insulated tank. A third heating device may be installed under the gear pump. As a second heating device, thermal electric heaters can be used. As a third heating device, thermal electric heaters can be used. All valves can be made with remotely controlled actuators. The device may include a control unit connected by electrical communication with all remotely controlled drives. In tanks, behind the pump and at the exit temperature sensors can be installed. The device may include a control unit connected by electrical connections to temperature sensors. The device may include sensors for the speed of the pump shafts and the mixing device. The device may include a control unit connected by electrical communication with speed sensors. The device may include a pressure sensor installed behind the pump. The device may comprise a control unit electrically connected to a pressure sensor. The device may contain an operator’s workstation which includes a system unit, a monitor, a keyboard and a mouse-type manipulator connected by electrical connections.

The invention is illustrated in figure 1 ... 9, where:

figure 1 shows the installation diagram,

figure 2 shows the second variant of the installation diagram,

figure 3 shows a third installation option with a control unit,

figure 4 shows the fourth installation option with controlled valves,

figure 5 shows the fifth installation option with temperature sensors,

figure 6 shows the sixth installation option with a computer,

Fig.7 shows the design of additional insulated tanks,

Fig.8 shows the design of the gear pump,

figure 9 shows the design of a gear pump with heating.

A device for the preparation of modified rubber-bitumen mastics (figure 1 ... 9) contains a thermally insulated tank 1 for heating bitumen with the first heater 2 (heating elements) and neck 3. The first heating device 2 is made in the lower part of the insulated tank 1 (figure 1) and placed on the entire length of the tank 1 on heat-resistant bricks. Bricks are covered by thermal insulation (in figure 1, heat-resistant bricks are not shown).

The heat-insulated container 1 contains an inner wall 4, an outer shell 5, which is made of fiberglass impregnated with rosin, and thermal insulation 6 between them. Thermal insulation 5 is made of polyurethane foam. The heat-insulated container 1 contains a side wall 7 and ends 8. A selection pipe 9 with a shut-off valve 10 is connected to one of the ends 8; a drain pipe 11 with a drain valve 12 and a bypass pipe 13 connected to the inlet of the intermediate container 14 are connected to the outlet mixing mastic 15 with polymer additives 16. The intermediate container 14 is equipped with a lid 18 connected to it by means of the loop 17. The intermediate thermally insulated container 14 is equipped with a second heater 19 (one or several ko heaters, heating electric heaters). A pipe 20 having flanges 21 connected to the inlet pipe 22 of the pump 23 is connected to the outlet of the intermediate tank 14, the outlet pipe of which 24 is connected to the neck 3 by a circulation pipe 25 with a valve 26. A cover 28 is installed on the neck 3 on the hinges 27.

All pipelines and valves are thermally insulated, for example, with polyurethane foam. This will reduce the loss of thermal energy to the environment.

The length of the pipeline 20 is 10 ... 15 cm to heat the remaining mastic in it during a break in the installation. To the outlet of the pump 23 is also connected a distribution pipe 29 with a valve 30. To the driven pulley 31 of the pump 23 by a belt drive 32, the drive pulley 33 of the drive 34 (electric motor). Pump 23 - gear type.

Inside the thermally insulated container 1, a mixing device 35 can be installed, which can be implemented in different ways. Figure 1 shows a variant with a horizontal shaft 36 to which radial blades 37 and a driven sprocket 38 are attached, connected by a chain gear 39 to the drive sprocket 40 of the gearbox 41, to which the drive 42 is attached. (A belt drive can be used instead of a chain gear.) gear 39 has a protective guard, which is not shown in FIG. As the drive 42, an electric motor is used. It is predominantly intended to use three-phase asynchronous motors with a supply voltage of 380 V as drives 34 and 42.

The shaft 36 of the mixing device can be installed perpendicular to the longitudinal axis of the insulated tank (in figure 1 ... 9 this option is not shown).

A possible embodiment of the installation (FIGS. 2 and 7) using a third heaters 43 installed under the pump 23 (the third heater 43 is also made in the form of one or more thermal electric heaters - electric heaters with terminals 44).

The installation may include a control unit 45, which is connected by power cables 46 to the heaters 2, 19 and 43 (figure 3).

To fully automate the process of controlling the preparation of the modified rubber-bitumen mixture, valves 10, 12, 26 and 30 should be equipped with remotely controlled actuators 47, 48, 49 and 50, respectively (Fig. 4), this will open and close all valves remotely. 47-50 controlled drives are not thermally insulated to avoid overheating.

To control the process of preparing mastic, it is advisable to use four temperature sensors (figure 5):

- the first temperature sensor 51 - T1 in a thermally insulated tank 1,

- the second temperature sensor 52 - T2 in an additional insulated tank 14,

- the third temperature sensor 53 - T3 temperature of the pump 23,

- the fourth temperature sensor 54 - T4. The temperature of the mastic at the outlet.

In addition, the device (Fig. 5) may include a first speed control sensor 55 mounted on the shaft of the pump 23 and a second speed control sensor 56 mounted on the horizontal shaft 36 of the mixing device 35 and a pressure sensor 57 installed at the outlet of the pump 23 (figure 5). These sensors monitor the operation of the pump 23 and the mixing device 35.

Temperature sensors 51 ... 54 are connected by electrical connections 58 to the control unit 45. This will allow controlling the temperature of the mastic in the insulated tank 1, in the additional insulated tank 14 and the temperature of the pump 23 to prevent it from sticking when the mastic hardens in the interval between its preparation cycles.

The most automated installation option is shown in Fig.6. It additionally contains an operator’s workstation 59 connected by electrical communication 58 (wired through a modem or wireless). The operator’s workstation 59 is equipped with a system unit 60, a monitor 61, a keyboard 62, and a mouse-type manipulator 63.

Figure 7 shows the design of an additional thermally insulated container 14, which contains a lid 18 attached to the loop 17 for sealing this container during operation, the bottom 64, the side wall 65. The additional thermally insulated container 14 has an inner metal wall 66, an outer wall 67 and thermal insulation 68 On the bottom 64, heat-resistant bricks 69 are laid on which a second heater 19 is installed. A second heater 19 is needed to supply additional heat necessary to dissolve the mastic components and compensate heat loss when the first heater 2. is off. The cover 18 also has thermal insulation 70. An inlet and an outlet pipe 71 and 72 are connected to an additional thermally insulated tank 14.

For installation, it is proposed to use a gear type pump 23 (Figs. 8 and 9) for better mixing of the mastic and, in addition, apply heating to prevent it from jamming. The pump 23 contains an inlet pipe 22, an output pipe 24. The pump 23 (Fig. 8) contains:

1. drive shaft 73,

2. pinion gear 74,

3. driven shaft 75,

4. driven gear 76,

5. housing 77,

6. upper case 78,

7. lower case 79.

The pump 23 is placed in the tank 80 and filled with insulating material 81. Under the pump 23, heat-resistant bricks 82 are laid on which a third heater 43 is installed (Fig. 9). This design will eliminate the jamming of the pump 23 after a long break in work. In addition, the design of a commercially available pump 23 can be slightly modified: the gaps between the driven and pinion gears are increased to prevent jamming and high-temperature graphite lubrication of the bearings of the pump 23 is applied (bearings 1–9 are not shown).

The installation can be placed on the trailer (figure 1 ... 9 is not shown). The trailer, depending on the volume of the insulated tank, can be uniaxial or biaxial. Other trailer options are also possible, such as railway wagons or multi-axle trailers for tractors.

Based on the proposed technical solution, plants of various dimensions and capacities can be manufactured.

Calculation of the power of the first heater

Heat capacity of bitumen C = 0.47 kcal / kg ° C

Bitumen mass 5000 kg

Heated 100 ° C

The amount of thermal energy 230,000 kcal = 225 kW hour.

Heating time 5 hours.

Heater power 50 kW

Installation Feature:

Trailer biaxial Trailer dimensions 5 m × 3.2 m × 2.2 m Installation weight 10,000 kg Capacity volume 6 cc m Mastic Weight 5000 kg Performance 200 tons per day Power of the first heater 50 kW Power of the second heater 5 kW Power of the third heater 2 kW Mixing drive power 11 kW Pump drive power 7.5 kW Supply voltage 380 V

It is possible to manufacture according to the proposed method and installations with lower or greater productivity.

Installation Equipment

The type of electric motors AIRM-516056 is 11 kW, 970 rpm and 5AMMX16056, 7.5 kW

Magnetic actuators PAE 512 alternating current 380 V with TRP 155 100A,

Circuit breakers A 3776 P-1R20 100A Iotc = 1000.

Perhaps the use of other types of equipment.

Calculation of energy loss due to natural convection

It takes the coefficient of heat transfer during natural convection into the environment - 20 kcal / m ² hour ° C.

The side surface of the insulated tank is 30 sq.m.

The temperature difference between the surface of the insulated tank and the environment is 10 ° C.

As a result, heat loss will amount to

Q = 20 × 30 × 10 = 6000 kcal / hour.

This corresponds to a power of 5 kW, i.e. power of the second heater 5 kW.

Proof of the optimality of the temperature of the mastic in the method

The minimum temperature T1 is determined by the viscosity of the mixed composition, and the maximum by energy loss due to natural convection, which is reflected in Table 1.

Table 1 Proof of temperature optimality T1 T1 ° C 80 90 one hundred 120 140 Mixing Energy kW twenty 16 fifteen fourteen 13.5 Power dissipation kW 4,5 4.8 5,0 6.0 8.2 Optimal mode

Proof of the optimality of the composition of the mastic

To optimize the composition of the mastic, laboratory work was carried out with various compositions, see Tables 2 and 3.

Table 2 The proof of the optimality of the composition for the addition of rubber crumb % rubber crumb 7% 10% fifteen% twenty% 25% thirty% Elongation at break,% thirty 34 45 46 48 Not less than 50 Strength at the time of rupture, MPa 0.06 0,07 0.09 0.1 0.12 0.14 Adhesion, MPa 0.1 0.12 0.18 0.3 0.32 0.35 Water resistance,% 0,07 0.1 0.15 0.2 0.22 0.24 Heat resistance 80 90 one hundred 110 115 120 ° C Density, kg / m ³ 1400 1350 1200 1100 1000 900 Optimally

For the addition of polyethylene, an additional thermally insulated container 14 of a smaller volume is used, of the order of 0.1 ... 0.2 m ³ . This will reduce energy costs, since there will be no need to heat a large capacity tank. As a result, this will reduce the cost of the mastic (Table 3).

Table 3 Proof of the optimality of the composition for the addition of polyethylene (At 20% rubber crumb, mass.) % polyethylene 0.7% 1,0% 1.5% 2.0% 2.5% Elasticity,% 48 47 45 44 thirty Strength, MPa 0.09 0.1 0.12 0.14 0.16 Cost, rub. kg 10 eleven 12 13 twenty Optimally

Conclusion: the optimal composition of the mastic:

- rubber crumb 10 ... 20%,

- polyethylene 1 ... 2%.

Perhaps the addition of waste oil.

Installation work

During installation, the trailer is transported by the tractor to the place of work, i.e. directly to the wall of the building where the roof is being repaired.

In the initial position, all valves 19, 12, 26 and 30 are closed. In the insulated container 1 through the neck 3, the main filler is poured (for example, rubber crumb from 10% to 20%). From the control unit 45 (Fig.3 ... 5) include the first heater 2.

Then include a drive 42 for mixing heated bitumen with crumb rubber. The necessary additives are poured into the intermediate container 14: polyethylene, in an amount of 1 ... 2%. After reaching the set temperature T1, the valves 10 and 26 are opened and the actuator 34 is turned on, which drives the shaft of the pump 23. The pump 23 repeatedly returns the mixture of bitumen with additives to the tank 1, while mixing them. The pump 23 must provide at least 20-fold exchange of the mastic in a thermally insulated tank 1. For example, with a volume of mastic of 6 cubic meters, pump 23 must provide a capacity of 120 cubic meters per hour or 2 cubic meters per minute. The use of the gear pump type 23 will allow better mixing of the additives with bitumen, and the use of the second heater 19 (Fig. 7) will ensure their melting and compensate for heat loss in the insulated tank 1.

After preparing the mastic, after 2..3 hours, close the valve 26 and open the valve 30. The mastic enters through pipeline 29, is fed to the roof of the building for its application using special technology. The process of applying mastic to the roof can be fully automated using a computer, Fig.6.

The use of the control panel 45 allows you to set the limit temperature of the mastic T1 and T2, which is controlled by temperature sensors 51 and 52, automatically turn off part of the first heaters 2 and change the speed of rotation of the shaft 36 of the mixing device 35.

Optimum temperatures

T1 = 90 ... 120 ° C

T2 = 130 ... 170 ° C, i.e. heating in an additional thermally insulated container 14 should be from 30 to 50 ° C.

When applying mastic to the roof, the required temperature T4 is maintained. It is also recommended that T4 = 130 ... 170 ° C, but to maintain it, you must turn on the third heater 43.

The application of the proposed group of inventions allowed:

1. Get different types of mastics that have high strength, elasticity, resistance to aging and aggressive environments, low and high temperatures and other properties. They produce plastic mastics, elastic, drying, non-drying.

2. To develop the most optimal and very cheap composition of the mastic and the optimal temperature regime for its preparation, eliminating overheating and uneven mixing.

3. To provide increased durability of the roof being repaired.

4. Get a seamless roofing membrane over the entire area of the reconstructed roof area.

5. To increase the productivity of the process and reduce energy consumption due to thermal insulation of the tank and pipelines and mixing.

6. Reduce the cost of equipment and produced mastic, reduce the cost of roofing.

7. Ensure the continuity of the roof repair process.

8. To ensure the environmental friendliness of the process due to the tightness of containers and all systems and the use of heating elements for melting bitumen and heating additives.

9. Provide full automation of the process.

10. Ensure the safety of work, eliminate burns and leakage of tar in the installation. Ensure the operator’s work in comfortable conditions, indoors at any distance from the installation.

Claims (14)

1. A method of preparing a modified rubber-bitumen mastic, including heating bitumen to a temperature of 90 ... 120 ° C in a thermally insulated container, adding crumb rubber and polyethylene, characterized in that only rubber crumbs in an amount of 10 ... 20% of the mass are added to the insulated container in bitumen mix, and in an additional heat-insulated sealed container pour polyethylene in an amount of 1 ... 2% of the mass and fill it with gravity-fed mixture of bitumen with crumb rubber, then the resulting mixture is heated additionally temperature of 130 ... 170 ° C and using a gear pump is carried out multiple recycling the mixture through an insulated container. 2. The method according to claim 1, characterized in that the recirculation is carried out for 1.5 ... 2 hours. 3. A device for preparing a modified rubber-bitumen mastic containing a thermally insulated container for heating bitumen with a heating device, a neck and a mixing device, a stirring drive, a shut-off valve, a drain line and pipelines, characterized in that a tight seal is installed between the shut-off valve and the neck below the level of the insulated tank thermally insulated additional tank, with a second heating device, a pipe is connected to the outlet from the intermediate tank recirculation wire and gear pump with drive, the outlet of the recirculation pipeline is connected to the neck of a thermally insulated tank. 4. The device according to claim 3, characterized in that a third heating device is installed under the gear pump. 5. The device according to claim 3 or 4, characterized in that thermal electric heaters are used as the second heating device. 6. The device according to claim 4, characterized in that thermal electric heaters are used as the third heating device. 7. The device according to claim 3 or 4, characterized in that all the valves are made with remotely controlled actuators. 8. The device according to claim 7, characterized in that it contains a control unit connected by electrical connections to all remotely controlled drives. 9. The device according to claim 3 or 4, characterized in that in the containers, behind the pump and at the outlet, temperature sensors are installed. 10. The device according to claim 9, characterized in that it comprises a control unit connected by electrical connections to temperature sensors. 11. The device according to claim 3 or 4, characterized in that it contains sensors for the frequency of rotation of the pump shafts and the mixing device. 12. The device according to claim 11, characterized in that it comprises a control unit connected by electrical connections to speed sensors. 13. The device according to claim 3 or 4, characterized in that it contains a pressure sensor installed behind the pump. 14. The device according to item 13, characterized in that it contains a control unit connected by electrical communication with the pressure sensor.

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