US20070039520A1 - Method for producing bituminous compositions - Google Patents

Method for producing bituminous compositions Download PDF

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Publication number
US20070039520A1
US20070039520A1 US11/457,931 US45793106A US2007039520A1 US 20070039520 A1 US20070039520 A1 US 20070039520A1 US 45793106 A US45793106 A US 45793106A US 2007039520 A1 US2007039520 A1 US 2007039520A1
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Prior art keywords
bitumen
alkyl
modified
emulsion
aggregate
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US11/457,931
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English (en)
Inventor
Everett Crews
Humbert Dellicolli
Willer deOliveria
Iain Jack
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WestRock MWV LLC
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Meadwestvaco Corp
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Application filed by Meadwestvaco Corp filed Critical Meadwestvaco Corp
Priority to US11/457,931 priority Critical patent/US20070039520A1/en
Assigned to MEADWESTVACO CORPORATION reassignment MEADWESTVACO CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DEOLIVEIRA, WILLER, CREWS, EVERETT, DELLICOLLI, HUMBERT THOMAS, JACK, IAIN
Publication of US20070039520A1 publication Critical patent/US20070039520A1/en
Priority to US11/862,273 priority patent/US7905949B2/en
Priority to US12/905,886 priority patent/US7972429B2/en
Priority to US13/116,517 priority patent/US8088210B2/en
Priority to US13/309,622 priority patent/US8444760B2/en
Priority to US13/866,166 priority patent/US9260608B2/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L95/00—Compositions of bituminous materials, e.g. asphalt, tar, pitch
    • C08L95/005—Aqueous compositions, e.g. emulsions
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D195/00—Coating compositions based on bituminous materials, e.g. asphalt, tar, pitch
    • C09D195/005—Aqueous compositions, e.g. emulsions
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C19/00—Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving
    • E01C19/02—Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving for preparing the materials
    • E01C19/10—Apparatus or plants for premixing or precoating aggregate or fillers with non-hydraulic binders, e.g. with bitumen, with resins, i.e. producing mixtures or coating aggregates otherwise than by penetrating or surface dressing; Apparatus for premixing non-hydraulic mixtures prior to placing or for reconditioning salvaged non-hydraulic compositions
    • E01C19/1059—Controlling the operations; Devices solely for supplying or proportioning the ingredients
    • E01C19/1068—Supplying or proportioning the ingredients
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2555/00—Characteristics of bituminous mixtures
    • C08L2555/20—Mixtures of bitumen and aggregate defined by their production temperatures, e.g. production of asphalt for road or pavement applications
    • C08L2555/26—Asphalt produced between 65°C and 100°C, e.g. half warm mix asphalt, low energy asphalt produced at 95°C or low temperature asphalt produced at 90°C
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2555/00—Characteristics of bituminous mixtures
    • C08L2555/40—Mixtures based upon bitumen or asphalt containing functional additives
    • C08L2555/50—Inorganic non-macromolecular ingredients
    • C08L2555/52—Aggregate, e.g. crushed stone, sand, gravel or cement
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2555/00—Characteristics of bituminous mixtures
    • C08L2555/40—Mixtures based upon bitumen or asphalt containing functional additives
    • C08L2555/80—Macromolecular constituents

Definitions

  • This invention relates to bituminous compositions, methods of producing the same, and pavement made from said bituminous compositions. More particularly, the invention relates to the production of bituminous compositions formulated with solvent-free bitumen emulsions which exhibit controllable, temperature-dependent interfacial rheology.
  • Cold mix paving compositions are made by mixing bitumen emulsion with aggregate at ambient temperature (i.e., temperature less than about 40° C.).
  • ambient temperature i.e., temperature less than about 40° C.
  • certain problems have traditionally been associated with the use of such compositions where no solvent is present.
  • a slow-setting bitumen emulsion in the construction of load-bearing pavements the pavement is slow to cure and develop sufficient strength values adequate to support heavy traffic and to resist moisture damage.
  • the use of a quick-setting bitumen emulsion often leads to premature breaking of the emulsion during handling and compaction (resulting in the formation of high air voids).
  • cutter stocks mineral oils and other solvents
  • the use of cutter stocks can also result in decreases in the early compressive strength of compacted pavement. Dosages of cutter stocks as little as 0.1% by weight of the emulsion often decreases the compacted pavement compressive strength until such time as the cutter stock has evaporated into the atmosphere.
  • Rapid-setting emulsions do not adequately coat dense-graded aggregates commonly used in construction of dense-graded, load-bearing pavements, because such rapid-setting emulsions tend to break immediately upon contact with mineral aggregate surfaces.
  • the term “rapid-setting” is a defining characteristic of such emulsions (i.e., they immediately rupture and liberate water upon contact with mineral aggregate).
  • load-bearing pavements are much thicker than the non-load-bearing surfaces produced by slurry seal coatings and micro-surfacings. The thicker load-bearing pavements must be compacted to densify the mixture, as insufficient density can lead to rapid failure of load-bearing pavements due to deformation, disintegration, and pot-hole formation.
  • Slow-setting emulsifiers are commonly employed in the production at ambient-temperature of emulsion-based road paving compositions for load bearing pavements.
  • Slow-setting emulsifiers produce bituminous emulsions which require little or no water to completely coat the aggregate surface.
  • the slow-setting nature of the emulsion yields a road paving composition with a controlled coalescence rate, so that the road paving mixture does not increase in viscosity to a point that it is unsuitable for handling, hauling, or compaction.
  • With highly dense, high-fines aggregate gradations slow-setting emulsions do not break either prior to or during compaction, thereby rendering the mixture easy to compact at ambient temperatures.
  • pavement compositions made at ambient-temperature with slow-setting bituminous emulsions are very slow to develop adhesion and cure to strengths sufficient to bear the stress of heavy traffic.
  • hot mix paving compositions do not contain bitumen emulsions, but are instead produced by mixing non-emulsified bitumen with aggregate at elevated temperatures (usually in excess of 140° C.).
  • the two most common hot mix facilities, drum mix plants and batch plants heat aggregate in a rotating kiln to extremely high temperatures to drive off all water adsorbed to the aggregate, as well as all water absorbed within the surface pores of the aggregate. Quantitative removal of water is required (1) to ensure complete aggregate coating and (2) to ensure that the finished hot mixture of aggregate and bitumen shows no moisture sensitivity in the finished pavement layer once it is transported, laid down, and compacted.
  • Hot, dry aggregate produced in conventional hot mix operations is mixed with bitumen (which is previously liquefied by heating to temperatures far in excess of its melting point) to produce what is known in the industry as the “hot mix asphalt.”
  • Hot mix asphalts generally must be produced, laid down, and compacted at temperatures in excess of about 160° C., as the compactability of the hot mix asphalt depends on the temperature. If the mix cools, the asphalt viscosity increases and the mixture cannot be compacted to the design density (known as percent air voids).
  • percent air voids design density
  • Another object of the present invention is to disclose bituminous compositions which are suitable for use in paving applications and to provide a paved road.
  • Yet another object of the present invention is to produce bituminous compositions at temperatures substantially below those of hot mix asphalt compositions.
  • a further object of the present invention is to produce bituminous compositions, using rapid-setting and/or quick-setting emulsifiers, which exhibit substantially complete aggregate coating, compact to required densities in the field, and which rapidly develop load-bearing strength.
  • bituminous compositions suitable for use in paving applications made by controlling temperature-dependent interfacial rheology in a broad range of solvent-free, high-residue bitumen emulsions containing bitumen.
  • emulsifiers are employed with structural characteristics that impart low interfacial viscosity, low Marangoni effect, and high interfacial bitumen solubility, at elevated temperatures.
  • bitumens in these emulsions with solubility parameters comparable with those of the emulsifier is preferred.
  • This invention teaches the formulation of solvent-free bitumen emulsions, which are based on bitumens and which exhibit controllable, temperature-dependent interfacial rheology, and use of said these emulsions to fully coat aggregate, thereby producing bituminous compositions suitable for the construction of load-bearing pavements that exhibit improved compaction to densities similar or superior to those achieved in hot mix asphalt compositions and achieve cure rates to traffic-ready strengths far in excess of those achieved with compacted, conventional cold emulsion-based paving compositions and equal or superior to those of compacted, hot mix paving compositions.
  • bituminous compositions When employed in paving applications, these bituminous compositions develop adhesive strength and load-bearing strength properties at rates comparable to traditional hot mix paving compositions and at rates faster than traditional cold mix paving compositions.
  • FIGS. 1, 2 , and 3 demonstrate the effect of exposing bitumen emulsions to increasing shear stresses, thereby illustrating the high shear stability at elevated temperature (e.g., 60° C.-80° C.) exhibited by the bitumen emulsions of the present invention.
  • FIG. 1 shows the shear stress evaluation of a solvent-free bitumen emulsion produced in Example 1 containing 0.5% by total weight of bitumen emulsion (bwe) of emulsifier (tallow polyalkylenepolyamines) at 60% residue of PG70-22 bitumen;
  • FIG. 2 shows the shear stress evaluation of a bitumen emulsion produced in Example 8 containing 1.0% bwe of emulsifier (modified tall oil fatty acid condensate of polyethylene polyamine) at 60% residue of PG64-22 bitumen; and
  • FIG. 3 shows the shear stress evaluation of a bitumen emulsion produced in Example 9 containing 0.75% bwe of emulsifier (a blend of modified and unmodified C16-C18 fatty acid condensate of polyethylene polyamine) at 60% residue of PG70-22 bitumen.
  • bituminous compositions of the present invention comprising bitumen emulsion and aggregate.
  • the bitumen emulsion is solvent-free and contains bitumen, an emulsifier, and water in an amount to complete the bitumen emulsion.
  • the bituminous composition is produced at a temperature from about 50° C. to about 140° C. by mixing:
  • bitumen emulsion comprises at least one bitumen.
  • the invention includes modified bitumens, and combinations thereof.
  • bitumens and “modified bitumens” are those which exhibit rheological properties that are appropriate for paving applications under specific climatic conditions, for example, those which conform to the Strategic Highway Research Program (SHRP) pavement binder specifications.
  • the bitumen component may be naturally occurring bitumens (such as Trinidad Lake asphalt and the like), or derived from crude oil. Also petroleum pitches (such as asphalt) obtained by a cracking process and coal tar can be used as well as blends of bituminous materials.
  • any additive which is traditionally added to bitumen to produce a modified bitumen meeting property specifications and performance standards are suitable.
  • additives include, but are not limited to, natural rubbers, synthetic rubbers, plastomers, thermoplastic resins, thermosetting resins, elastomers, and combinations thereof.
  • examples of these additives include styrene-butadiene-styrene (SBS), styrene-butadiene-rubber (SBR), polyisoprene, polybutylenes, butadiene-styrene rubbers, vinyl polymers, ethylene vinyl acetate, ethylene vinyl acetate derivatives, neoprene and the like.
  • the modified bitumen contain at least one member selected from the group consisting of styrene-butadiene-styrene, styrene-butadiene-rubber, sulfur-modified bitumen, acid-modified bitumen and combinations thereof. It is well within the ability of a skilled artisan to produce modified bitumen containing the noted additives.
  • additives traditionally employed in the production of bitumen emulsions may be incorporated into the aqueous phase of the bitumen emulsion in order to adjust the characteristics of the finished mix.
  • Suitable additives include styrene-butadiene-rubber latex, polyisoprene latex, neoprene, associative thickners, starches, salts, and the like.
  • bitumen emulsion of the present invention is comprised of at least one emulsifier.
  • Suitable emulsifiers include: amphoteric emulsifiers, cationic emulsifiers, nonionic emulsifiers and combinations thereof.
  • Bitumen emulsions are of the oil-in-water type; they consist of a suspension of bituminous particles dispersed in the water phase. These particles have, in the case of cationic emulsions, a positive charge.
  • the pH of cationic emulsions is below pH 7.0.
  • amphoteric emulsifiers are characterized by the capacity to lower interfacial tensions between dissimilar materials (e.g., bitumen and water) at pH values both above and below 7.0.
  • the charge of the disperse-phase oil droplets in amphoteric emulsions may be either positive or negative. It is well within the ability of those skilled in the art to combine the bitumen and the emulsifiers taught herein to prepare the solvent-free bitumen emulsions of the present invention.
  • Ionic emulsifiers which are suitable for use in the present invention include amphoteric emulsifiers, cationic emulsifiers, and combinations thereof.
  • amphoteric emulsifiers includes both mono-amphoteric and polyamphoteric emulsifiers.
  • Amphoteric emulsifiers which are suitable for use in the present invention include, but are not limited to, the following: C-12 to C-24 (preferably C-16 to C-18) fatty acids, rosin acids, and combinations thereof modified with acrylic acid, maleic anhydride, fumaric acid, and/or other ene- and dieneophiles and further reacted with polyethylene polyamines, lithium C-12 to C-24 alkyl amidopropyl halide methyl carboxylate betaines, sodium C-12 to C-24 alkyl amidopropyl halide methyl carboxylate betaines, potassium C-12 to C-24 alkyl amidopropyl halide methyl carboxylate betaines, lithium C-12 to C-24 alkyl amidopropyl halide phosphate betaines, sodium C-12 to C-24 alkyl amidopropyl halide phosphate be
  • Cationic emulsifiers which are suitable for use in the present invention include, but are not limited to, the following: fatty imidazolines derived from C-12 to C-24 fatty acids, fatty imidoamines derived from C-12 to C-24 (preferably C-16 to C-18) fatty acids, rosin acids, and combinations thereof modified with maleic anhydride, fumaric acid, and/or other ene- and dieneophiles and further reacted with polyalkylenepolyamines; fatty amidoamines derived from C-12 to C-24 (preferably C-16 to C-18) fatty acids, rosin acids and combinations thereof modified with acrylic acid, maleic anhydride, fumaric acid, and/or other ene- and dieneophiles and further reacted with polyalkylenepolyamines; saturated C-12 to C-24 alkyl monoamines, unsaturated C-12 to C-24 alkyl monoamines, saturated C-12 to C-24 alkyl polypropylenepolyamines; unsaturated C
  • the cationic emulsifier be a member selected from the group consisting of saturated C-12 to C-24 alkyl monoamines, unsaturated C-12 to C-24 alkyl monoamines, saturated C-12 to C-24 alkyl polypropylenepolyamines, unsaturated C-12 to C-24 alkyl polypropylenepolyamines, and combinations thereof. It is further preferred that the cationic emulsifier be a blend of at least one member selected from the group consisting of saturated and unsaturated C-12 to C-24 alkyl monoamines with at least one member selected from the group consisting of saturated and unsaturated C-12 to C-24 alkyl polypropylenepolyamines. As used herein, the term “cationic emulsifiers” includes the above-noted compounds and their derivatives.
  • the emulsifiers of the present invention not only convey the high-temperature shear-stability needed for mixing (and subsequent compacting) of the bituminous compositions, but also impart a high viscosity to the bitumen emulsion (so that no thickener is needed for emulsion stability or for increased film coating on the aggregate) to enhance bitumen wetting of the aggregate surface, and to lower interfacial tension between the bitumen film and aggregate (so that a strong adhesive bond is maintained and water damage to the pavement is prevented).
  • Emulsifier formulations are further classified as rapid-setting (i.e., spray-grade), quick-setting, and slow-setting depending on the speed with which a given emulsion, using an economical dosage of emulsifier, will break upon contact with mineral aggregate. While rapid-setting, quick-setting, and slow-setting emulsifiers are suitable for use in the present invention, it is preferred to employ rapid-setting or quick-setting emulsifiers. It is further preferred to employ rapid-setting emulsifiers with dense-graded aggregate.
  • bitumen emulsion be solvent-free.
  • Environmental concerns have driven the reduction, up to elimination, of organic solvents from paving bitumen emulsions. However, for technical reasons total elimination has not been available in all paving applications prior to the availability of the present invention.
  • solvent-free is defined to include a minor portion of organic solvents. For example, “solvent-free” has at one time been defined in the state of Pennsylvania to include up to 4% organic solvents.
  • the bitumen emulsion may contain at least one solvent (such as naphtha, kerosene, diesel, flux, and the like) at a level less than that needed to facilitate either: 1) the mixing of the bituminous composition at ambient temperature to yield fully-coated aggregate, or 2) the compaction of the bituminous composition at ambient temperatures.
  • the level of solvent be less than about 1.0% by total weight of the bitumen emulsion.
  • ambient temperatures means an environmental temperature of less than about 40° C.
  • bitumen emulsions of the present invention may be stored at temperatures in the range of about 60° C. to about 80° C. for prolonged periods of time without adversely affecting the particle size distribution of the emulsions.
  • bituminous compositions of the present invention are produced at a temperature in the range of about 50° C. to about 140° C. (preferably in the range of about 55° C. to about 120° C., and more preferably in the range of about 60° C. to about 80° C.) by mixing from about 2.0% to about 10% by total weight of the bituminous composition of the bitumen emulsion at a temperature in the range of about 25° C. to about 95° C. (preferably in the range of about 60° C. to about 80° C.), and from about 90% to about 98% by total weight of the bituminous composition of aggregate at a temperature in the range of about 60° C. to about 140° C. (preferably in the range of about 60° C. to about 120° C.).
  • the bitumen emulsion may be mixed cold (e.g., at ambient temperatures) and then heated.
  • Aggregate used in paving materials and road construction, road rehabilitation, road repair, and road maintenance are derived from natural and synthetic sources.
  • aggregate are selected for asphalt paving applications based on a number of criteria, including physical properties, compatibility with the bitumen to be used in the construction process, availability, and ability to provide a finished pavement that meets the performance specifications of the pavement layer for the traffic projected over the design life of the project.
  • gradation refers to the percent of aggregate particles of a given size. For most load-bearing asphalt pavements, three gradations are common: dense-graded, gap-graded, and open-graded. Dense-graded aggregate exhibit the greatest mineral surface area (per unit of aggregate).
  • Open-graded aggregate largely consist of a single, large-sized (e.g., around 0.375 to 1.0 inch) stone with very low levels (typically less than about two percent of the total aggregate) of fines (material less than 0.25 inch) or filler (mineral material less than 0.075 mm). Gap graded aggregate fall between dense-graded and open-graded classes.
  • Reclaimed asphalt pavement (RAP) material generally reflects the gradation of the pavement from which the reclaimed material was obtained. If the original pavement was a dense-graded mix, the RAP will also be dense graded, although the filler content is generally observed to be lower than the design limits of the origin aggregate specifications.
  • Any aggregate which is traditionally employed in the production of bituminous paving compositions is suitable for use in the present invention, including dense-graded aggregate, gap-graded aggregate, open-graded aggregate, reclaimed asphalt pavement, and mixtures thereof. Aggregate which is not fully dried can be employed in the present invention.
  • bituminous compositions of the present invention be applied to the surface to be paved at a temperature in the range of about 50° C. to about 120° C. (preferably in the range of about 55° C. to about 100° C., and more preferably in the range of about 60° C. to about 80° C.).
  • bituminous compositions of the present invention can be compacted as desired using any of the compaction methods traditionally employed for paving applications. It is preferred that the applied bituminous compositions be compacted to an air void content comparable to hot mix pavement compositions made at temperatures exceeding 140° C. having substantially equivalent aggregate gradation and bitumen content.
  • the applied bituminous compositions be compacted to an air void content lower than comparable cold mix pavement compositions made at ambient temperatures (i.e., temperatures less than about 40° C.) having substantially equivalent aggregate gradation and bitumen content.
  • the applied bituminous compositions be compacted to develop load-bearing strength at a rate comparable to hot mix pavement compositions made at temperatures exceeding 140° C. having substantially equivalent aggregate gradation and bitumen content.
  • the applied bituminous compositions be compacted to develop load-bearing strength at a faster rate than that developed by comparable cold mix pavement compositions made at ambient temperatures having substantially equivalent aggregate gradation and bitumen content.
  • Strength development in cold mix pavement compositions is a function of the development of adhesion between bitumen and aggregate. It is, therefore, preferred that the applied bituminous compositions be compacted to develop adhesion between bitumen and aggregate at a faster rate than that developed by comparable cold mix pavement compositions made at ambient temperatures having substantially equivalent aggregate gradation and bitumen content.
  • the method of the present invention is suitable for use in thin lift overlay paving applications.
  • Thin lift overlays is a maintenance paving technique that traditionally involves the placement of a thin lift of a bituminous composition produced according to standard hot-mix procedures at temperatures normally exceeding 165° C. and applied at corresponding temperatures in the field to an existing, damaged or distressed pavement surface.
  • the current thin lift technology using hot-mix bituminous compositions commonly suffers from two chief deficiencies.
  • the hot bituminous compositions tend to cool quickly, making it difficult to extend (i.e., spread) onto the existing pavement surface (at ambient temperatures) that is in need of maintenance or repair. This rapid cooling of the thin lift of hot bituminous material can cause compaction difficulties.
  • bituminous compositions of the present invention can be employed in the production of bituminous paving blocks.
  • bitumen emulsion and aggregate are mixed to form a bituminous composition that is cast in molds, compacted, and allowed to cure.
  • the cured blocks (or bricks) are used to construct pavements.
  • bituminous compositions of the present invention be cast in the mold and compacted at a temperature in the range of about 50° C. to about 120° C. (preferably in the range of about 55° C. to about 100° C., and more preferably in the range of about 60° C. to about 80° C.).
  • bituminous compositions of the present invention Due to the enhanced compaction (leading to higher density and higher strength) and accelerated cure rates (leading to increased production rates and improved manufacturing economics) exhibited by the bituminous compositions of the present invention, the employment of the methods and bituminous compositions of the present invention offers improvements over the construction of these blocks using traditional cold mix paving compositions.
  • Bituminous compositions of the present invention should be maintained at a temperature in the range of about 50° C. to about 120° C. (preferably in the range of about 55° C. to about 100° C., and more preferably in the range of about 60° C. to about 80° C.) for the period of time between the production of the bituminous compositions and their use in paving applications. It is preferred that the bituminous compositions be maintained at these temperatures in closed systems (such as relatively large stockpiles, storage silos, covered transport vehicles, and the like) to prevent evaporation of moisture.
  • closed systems such as relatively large stockpiles, storage silos, covered transport vehicles, and the like
  • Equipment traditionally utilized in the production of asphalt emulsion mixes includes pug mills of either batch or continuous variety.
  • Pug mills impart high shear to the emulsion as it is ground with coarse aggregate, fines, and filler.
  • Hot mix asphalt compositions are typically produced in continuous or batch operations.
  • Continuous plants typically use drum mixtures of either parallel flow or counter flow variety.
  • These mixers are high shear mixers as aggregate (which is heated in the drum or batch mixer to the specified process temperatures) tumbles down the inclined drum and as bitumen emulsion is sprayed onto the warm aggregate.
  • the emulsion treated aggregate also tumbles downward through the drum mixer.
  • the interior wall of most drum mixers is lined with vanes that repeatedly catch the mix, lift it up as the drum rotates, and deposit it back to the bottom of the drum.
  • Drum and batch plants are capable of throughput of many hundred tons of paving material per hour. While it is preferred to employ drum mixers or batch mixers in the production of the bituminous compositions of the present invention, any method of mixing bitumen emulsion and aggregate traditionally utilized in the production of paving compositions can be used.
  • a common problem associated with the high shear event of mixing has been a coarsening of the emulsion.
  • the emulsifier formulations described herein impart high-temperature rheological properties to the solvent-free emulsion, which in turn stabilize the emulsion against the mechanical stresses imparted on the emulsion by the mechanical action of mixing with aggregate at elevated temperatures.
  • These mechanical and shear stresses have commonly caused a coarsening of the emulsion with most traditional emulsifier formulations, leading to a reduction in the degree of aggregate coating and an increase in the viscosity of the mix, with the latter resulting in poor densification of the paving composition during compaction.
  • the rheology of the disperse-phase droplets in the bitumen emulsions of the present invention directly influences the behavior of the emulsions when mixed at elevated temperatures with heated aggregate.
  • the rheology at the oil-water interface is, in turn, controlled by the structure and chemistry of the emulsifiers.
  • Emulsifier structure and chemistry affect the energy required to disperse the emulsifier at the interface.
  • Emulsifier structure and chemistry determine the shear stability of the oil-water droplets against coalescence under high-temperature shear conditions, such as those exhibited during mixing of emulsions and aggregate at temperatures above ambient.
  • Emulsifier structure and packing affect the interfacial fluidity or viscosity. Further, proper choice of emulsifier structure affects the magnitude of the effect on the interfacial viscosity.
  • bitumen emulsions which behave as desired have higher levels of shear stability than those which do not show this behavior would suggest this chemical contribution results from the emulsifier.
  • strength development in the bituminous compositions of the present invention is associated with better compressibility than traditional cold mixes very strongly suggests that the specific physico-chemical effect is a change in the rheology of the bitumen droplets within the emulsion.
  • the early strength development exhibited by the bituminous compositions of the present invention which is more characteristic of a hot mix than a cold mix also indicates that the rheological response of the bitumen droplets is an interfacial rather than a bulk response.
  • a variant of the above mechanism which is consistent with the currently available data and observations of the present invention consists of a heat dependant activation of the interfacial solubility of the ionic emulsifier.
  • Interfacial solubility within the present context may be defined as localization of the emulsifier at the interface.
  • the emulsifier resides not within the aqueous phase of the bitumen emulsion but at the interface with certain functional groups penetrating into the bitumen
  • penetration of the interface by the emulsifier residing within the surface of the bitumen droplet with functional groups oriented towards the water and others oriented towards the interior of the bitumen phase of the bitumen emulsion
  • complete residence within the bitumen phase of the bitumen emulsion but at the interface the mirror image of surface adsorption.
  • the interactions of the emulsifier with the interfacial region of a dispersed bitumen droplet can influence the interfacial rheology of the bitumen in two ways.
  • the emulsifier can provide a lubricity layer or slip plane between and amongst the droplets or they can disrupt the structure of the asphaltene fractions of the bitumen at and within the interface. It must be noted that the hardness and flow resistance of bitumen is to a large degree a function of the asphaltene components within a particular bitumen.
  • the model of bitumen favored by those working in the area of heavy oil processing consists of asphaltenes of varying molecular weights existing as dissolved and colloidal entities within the maltene phase of the bitumen.
  • the resistance to flow is referred to as viscosity.
  • a foreign molecule or parts of that molecule must have similar cohesive energy density to the asphaltenes. From a thermodynamic point of view, this means that if the molecules of two different substances have similar cohesive densities and are placed in close proximity to each other and subjected to the same conditions (such as temperature, pH, ionic strength etc.) the molecules of the two will intermingle at the level of individual molecules. This is by definition solvation or dissolution.
  • the substance present in greater concentration is referred to as the solvent and the other, the solute.
  • solubility parameter This number is actually the square root of the cohesive energy density.
  • solubility parameter a parameter that has been proposed. The most widely referred to models are those of Hildebrand and Hansen.
  • ⁇ solubility parameter
  • asphaltenes have a solubility parameter ( ⁇ ) of 19-24 (MPa) 1/2 . Consequently, a substance with a solubility parameter within or slightly above this range should in principle dissolve in and disrupt the internal structure of the asphaltenes of an asphalt.
  • solubility parameters in the range of 19-25 (MPa) 1/2 or higher will identify molecules or parts of molecules which have the ability to disrupt asphaltene structure and consequently fluidize that bitumen, while molecules or parts of molecules with solubility parameters similar to those of the C5-C7 hydrocarbons have the potential to reflocculate or coagulate already dispersed asphaltenes.
  • the cohesive energy density or solubility parameter of a molecular is determined by its chemical composition or make-up. Consequently, it is also a function of the raw materials and the manufacturing process used to manufacture that substance, or more succinctly, the nature of the specific substance.
  • bitumen emulsions with emulsifiers comprised of functional groups and structure, which impart the requisite solubility characteristics (as described above) for controlling temperature-dependent interfacial rheology.
  • bituminous compositions of bitumen emulsion and aggregate were either mixed with an automated bucket mixer (Example 1) or by hand (Examples 2-14).
  • the mixtures of bitumen emulsion and aggregate were compacted immediately after preparation while the mixtures were at production temperatures.
  • a Strategic Highway Research Program (SHRP) gyratory compactor (commercially available from Pine Instruments) was used to compact the bituminous compositions into pills at a gyratory angle of 1.25° and a ram pressure of 600 kPa using 30 gyrations.
  • SHRP Strategic Highway Research Program
  • the bituminous composition pills were placed in a 25° C. oven for curing.
  • the pills were evaluated for compressive strength (i.e., Marshall stability).
  • the compressive strength value obtained after four hours of curing at ambient temperature (25° C.) is referred to herein as “early strength.”
  • a stabilometer (commercially available from Pine Instruments) was used to measure the compressive strength of the compacted specimens.
  • the mean particle sizes of each of the bitumen emulsions employed in the following examples were less than 10 microns.
  • the aggregate used in the following examples was crushed granite conforming to gradation and property specifications for a dense-graded, 1 ⁇ 2-inch nominal paving mixture commonly used for production of pavement wearing courses. All aggregate samples were oven- dried (110° C.) before usage to remove moisture. In the comparative cold mix examples, the aggregate was allowed to cool to room temperature before mixing with the bituminous emulsion. In the comparative hot mix examples, the aggregate was heated to a temperature in the range of about 140° C. to 160° C. before mixing with bitumen heated to an equivalent temperature. All graded aggregate samples were 1,000 grams.
  • Coating was measured using a modification of the commonly known instrumental luminescence method of Deneuvillers et al. Coating values in the examples below are expressed in percentages, indicating the measured percentage of aggregate surface coated by bitumen.
  • Bituminous compositions of the present invention were prepared by the following procedure.
  • Solvent-free bitumen emulsions were prepared using one of three different emulsifiers (A, B, and C) based on alkyl polyamines at dosages ranging from 0.3% to 0.5% by total weight of the respective bitumen emulsion.
  • Emulsifier A was a blend of 0.4% by total weight of the bitumen emulsion (bwe) of saturated and unsaturated C16-C18 tallow tripropylenetetramines and 0.1% bwe of saturated and unsaturated C16-C18 tallow monoamines.
  • Emulsifier B was 0.3% bwe of saturated and unsaturated C16-C18 tallow polypropylenepolyamine blends.
  • Emulsifier C was a blend of 0.45% bwe of alkyl polypropylenetetramine and 0.01%-0.05% bwe of a mixture of saturated and unsaturated C16-C18 alkyl monoamines, -diamines, and -triamines.
  • the respective emulsifiers were dissolved in warm water and treated with hydrochloric acid solution to lower the pH to 2.0.
  • the aqueous solution of emulsifier(s) in water (called the “soap solution”) was heated to 55° C. and added to an Atomix colloid mill.
  • bitumen employed in this example was of Venezuelan origin and had a performance-grade of PG64-22.
  • the bitumen was heated to 130° C. and added to the Atomix colloid mill, wherein the soap solution and bitumen mixture was processed to produce bitumen emulsion.
  • the bitumen content of the finished bitumen emulsions were about 60-63% bwe.
  • the bitumen emulsions were subsequently diluted with water to 53.3% bitumen content prior to mixing with aggregate.
  • the aggregate used was crushed granite conforming to gradation and property specifications for 1 ⁇ 2-inch nominal wearing course paving aggregate.
  • the aggregate as received from the quarry was oven dried to remove moisture.
  • the dried aggregate was separated into size fractions from particles passing the 12.5-mm sieve to particles passing the 0.075 micron sieve.
  • the fractions were combined in quantities to give an aggregate gradation conforming to the standard for 1 ⁇ 2-inch nominal, dense-graded aggregate for surface and wearing course pavements. This combination of aggregate water-free fractions meeting the 1 ⁇ 2-nominal gradation standard is referred to as the graded aggregate.
  • bituminous compositions made in this example according to the method of the present invention the graded aggregate was heated to about 80° C. in an oven while the bitumen emulsion was heated to about 60° C.
  • About 1,000 grams of heated graded aggregate were placed in a 1-gallon stainless steel bucket, and the bucket was placed in the automatic bucket mixer.
  • To the 1,000 grams of aggregate at 80° C. was added, with stirring, 90 g of 60° C. bitumen emulsion.
  • the mixing was continued for an additional 60 seconds to produce bituminous compositions containing about 4.8% bitumen by total weight of the graded aggregate.
  • bitumen compositions having a temperature in the range of about 60° C. to about 80° C.
  • the bitumen compositions were then compacted using 30 gyrations of a SHRP Pine gyratory compactor at 600 kPa pressure and a gyration angle of 1.25°.
  • the compacted bituminous compositions were placed in a 25° C. oven and allowed to cure for four hours. After four hours of curing, the physical and performance properties of the compacted and cured bituminous compositions were measured.
  • bituminous compositions were produced having equivalent aggregate gradation and bitumen content.
  • the procedure for the production of the bituminous composition of the present invention noted above was followed for producing these cold mix bituminous compositions with the exception that the bitumen emulsion and the graded aggregate were each at ambient room temperature (23° C.) when mixed in the bucket mixer.
  • the resulting cold mix bitumen compositions at ambient temperature were added immediately to a 100-mm diameter gyratory compaction mold, which was also at ambient temperature.
  • the ambient-temperature bitumen compositions were then compacted using 30 gyrations of a SHRP Pine gyratory compactor at 600 kPa pressure and a gyration angle of 1.25°.
  • the compacted bitumen compositions were placed in a 25° C. oven and allowed to cure for four hours. After four hours of curing, the physical and performance properties of the compacted and cured cold mix bituminous compositions were measured.
  • the bituminous compositions of the present invention had aggregate coating levels of 94% to 99%.
  • the mixes gave compacted bituminous compositions (pills) with heights ranging from 62.2 to 62.7 mm after compaction, which were substantially denser than the cold mix pills.
  • the same compacted bituminous compositions made according to the method of the present invention exhibited compressive strength (lb-f) values after storage at 25° C. four hours of 3,000-3,235 lb-f, which was substantially stronger than that exhibited by the cold mix examples.
  • this compressive strength value obtained after only four hours of curing at ambient temperature, is referred to herein as “early strength.”
  • the emulsion from Example 1 used in the evaluations shown in FIG. 1 contained 0.5% by total weight of bitumen emulsion (bwe) of emulsifier (tallow polyalkylenepolyamines) at 60% residue of PG64-22 bitumen.
  • the bitumen emulsions of the present invention exhibit high shear stabilities at the elevated temperatures of the present invention (i.e., about 50° C. to about 120° C.).
  • FIG. 1 shows the effect of exposing a bitumen emulsion (formulated and produced according to the teachings of this invention) to increasing shear rates using a TA Rheometer at varying temperatures. In these experiments, the shear rate was increased from 0 to 1,000 seconds-inverse in 120 seconds.
  • bituminous compositions made using the method of the present invention were also compared to the properties of bitumen and aggregate mixes made according to traditional hot mix asphalt methodologies. All bituminous compositions in this example contained commercially-available, performance-grade PG70-22 bitumen, and were prepared with a bitumen content of 4.8% by total weight of the graded aggregate.
  • Bituminous compositions of the present invention were prepared by the following procedure. Solvent-free bitumen emulsions were prepared using tallow polyalkylenepolyamines emulsifier at 1.0% by total weight of the bitumen emulsion (bwe). The emulsifier was dissolved in warm water and treated with hydrochloric acid solution to lower the pH to 2.0. The aqueous solution of emulsifier(s) in water (called the “soap solution”) was heated to 55° C. and added to an Atomix colloid mill.
  • bitumen employed in this example was a commercially-available, performance-grade PG70-22.
  • the bitumen was heated to 130° C. and added to the Atomix colloid mill, wherein the soap solution and bitumen mixture was processed to produce bitumen emulsion.
  • the bitumen content of the finished bitumen emulsion was about 60-63% bwe.
  • the bitumen emulsions were subsequently diluted with water to 53.3% bitumen content prior to mixing with aggregate.
  • bituminous compositions made in this example according to the method of the present invention the graded aggregate of Example 1 was heated to about 80° C. in an oven while the bitumen emulsion was heated to about 60° C. About 1,000 grams of heated graded aggregate were placed in a 1-gallon stainless steel bucket. To the 1,000 grams of aggregate at 80° C. was added 90 g of 60° C. bitumen emulsion. The mixture was stirred by hand for approximately 60 seconds to produce the bituminous compositions containing about 4.8% bitumen by total weight of the graded aggregate.
  • bitumen compositions having a temperature in the range of about 60° C. to about 80° C.
  • the bitumen compositions were then compacted using 30 gyrations of a SHRP Pine gyratory compactor at 600 kPa pressure and a gyration angle of 1.25°.
  • the compacted bituminous compositions were placed in a 25° C. oven and allowed to cure for four hours. After four hours of curing, the physical and performance properties of the compacted and cured bituminous compositions were measured.
  • a hot mix specimen having equivalent aggregate gradation and bitumen content was made according to standard laboratory procedures for the preparation of hot mix bituminous compositions.
  • Graded aggregate was prepared as in Example 1. About 1,000 grams of graded aggregate heated to 140° C. were placed in a 1-gallon stainless steel bucket. To the 1,000 grams of heated aggregate was added 48 grams of a PG70-22 bitumen, which had been previously heated to 140° C. The mixture was stirred by hand for approximately 30 seconds to distribute the bitumen over the surface of the hot aggregate. The coated aggregate was returned to the oven and heated until the temperature reached 140° C.
  • the resulting hot mix bituminous composition was removed and stirred a second time by hand for 30 seconds, then transferred to a 100-mm gyratory compaction mold which had been previously heated to 140° C.
  • the gyratory compaction mold and bituminous composition were returned to the 140° C. oven for 20 minutes.
  • the hot mix bitumen composition was then compacted using 30 gyrations of a SHRP Pine gyratory compactor at 600 kPa pressure and a gyration angle of 1.25°.
  • the compacted hot mix bituminous compositions were placed in a 25° C. oven and allowed to cure for four hours. After four hours of curing, the physical and performance properties of the compacted and cured hot mix bituminous compositions were measured.
  • a second compacted hot mix bituminous composition was prepared according to the aforementioned hot mix procedure except that the temperature used in all mixing, heating, and compaction steps was 160° C. instead of 140° C.
  • bituminous composition having equivalent aggregate gradation and bitumen content.
  • the procedure for the production of the bituminous composition of the present invention noted above was followed for producing these cold mix bituminous compositions with the exception that the bitumen emulsion and the graded aggregate were each at ambient room temperature (23° C.) when mixed in the bucket.
  • the resulting cold mix bitumen compositions at ambient temperature were added immediately to a 100-mm diameter gyratory compaction mold, which was also at ambient temperature.
  • the ambient-temperature bitumen compositions were then compacted using 30 gyrations of a SHRP Pine gyratory compactor at 600 kPa pressure and a gyration angle of 1.25°.
  • the compacted bitumen compositions were placed in a 25° C. oven and allowed to cure for four hours. After four hours of curing, the physical and performance properties of the compacted and cured cold mix bituminous compositions were measured.
  • Bituminous compositions of the present invention were produced and compacted using the procedure of Example 2.
  • Solvent-free bitumen emulsions were prepared using tallow polyalkylenepolyamines emulsifier at 0.5% by total weight of the bitumen emulsion (bwe).
  • the bitumen employed in this example was commercially-available, performance-grade PG64-22 bitumen modified with styrene-butadiene-styrene (SBS) polymer. All of the bituminous compositions in this example contained this modified PG64-22 bitumen, and each was prepared with a bitumen content of 4.8% by total weight of the graded aggregate.
  • SBS styrene-butadiene-styrene
  • bituminous composition For further comparison purposes a cold mix bituminous composition was also produced having equivalent aggregate gradation and bitumen content.
  • the procedure for the production of the bituminous composition of the present invention noted above was followed for producing these cold mix bituminous compositions with the exception that the bitumen emulsion and the graded aggregate were each at ambient room temperature (23° C.) when mixed in the bucket.
  • Bituminous compositions of the present invention were produced and compacted using the procedure of Example 2.
  • Solvent-free bitumen emulsions were prepared using alkyl alkylenepolyamine emulsifiers at dosages ranging from 1.0% to 0.5% by total weight of the bitumen emulsion (bwe).
  • the bitumen employed in this example was a commercially-available, performance-grade unmodified PG64-22. All of the bituminous compositions in this example contained this PG64-22 bitumen, and each was prepared with a bitumen content of 4.8% by total weight of the graded aggregate.
  • bituminous compositions were produced having equivalent aggregate gradation and bitumen content.
  • the procedure for the production of the bituminous composition of the present invention noted above was followed for producing these cold mix bituminous compositions with the exception that the bitumen emulsion and the graded aggregate were each at ambient room temperature (23° C.) when mixed in the bucket.
  • the pills made with the bituminous compositions of the present invention exhibited compressive strength values after curing at 25° C. for four hours which were 86%-163% stronger than the identically formulated, emulsion-based cold mix bituminous compositions made and compacted at ambient laboratory conditions. Additionally, the bituminous compositions of the present invention showed substantially improved densification when compared to the cold mix compositions. Likewise, the present bituminous compositions had calculated air voids (Pa) 2.76 to 3.72 percent points lower than the Pa values of the comparable cold mix specimens (each mm of pill height corresponds to roughly 1.2% air content in the specimen).
  • Bituminous compositions of the present invention were produced and compacted using the procedure of Example 2.
  • Solvent-free bitumen emulsions were prepared using tallow polyalkylenepolyamine emulsifier at dosages ranging from 1.0% to 0.5% by total weight of the bitumen emulsion (bwe).
  • the bitumen employed in this example was a commercially-available, performance-grade PG70-22. All of the bituminous compositions in this example contained this PG70-22 bitumen, and each was prepared with a bitumen content of 4.8% by total weight of the graded aggregate.
  • bituminous compositions were produced having equivalent aggregate gradation and bitumen content.
  • the procedure for the production of the bituminous composition of the present invention noted above was followed for producing these cold mix bituminous compositions with the exception that the bitumen emulsion and the graded aggregate were each at ambient room temperature (23° C.) when mixed in the bucket.
  • the pills made with the bituminous compositions of the present invention exhibited compressive strength values after curing at 25° C. for four hours which were 52%-142% stronger than the identically formulated, emulsion-based cold mix bituminous compositions made and compacted at ambient laboratory conditions. Additionally, the bituminous compositions of the present invention showed substantially improved compaction compared to the analogous cold mix compositions as measured by the heights of the pill specimens.
  • Bituminous compositions of the present invention were produced and compacted using the procedure of Example 2.
  • Solvent-free bitumen emulsions were prepared using tallow polyalkylenepolyamine emulsifier at dosages ranging from 1.0% to 0.5% by total weight of the bitumen emulsion (bwe).
  • the bitumen employed in this example was a commercially-available, performance-grade PG64-22 bitumen modified with styrene-butadiene-styrene block copolymer. All of the bituminous compositions in this example contained this modified PG64-22 bitumen, and each was prepared with a bitumen content of 4.8% by total weight of the graded aggregate.
  • bituminous compositions were produced having equivalent aggregate gradation and bitumen content.
  • the procedure for the production of the bituminous composition of the present invention noted above was followed for producing these cold mix bituminous compositions with the exception that the bitumen emulsion and the graded aggregate were each at ambient room temperature (23° C.) when mixed in the bucket.
  • the pills made with the bituminous compositions of the present invention exhibited compressive strength values after curing at 25° C. for four hours which were stronger than the identically formulated, emulsion-based cold mix bituminous compositions made and compacted at ambient laboratory conditions. Additionally, the bituminous compositions of the present invention showed substantially improved compaction compared to the analogous cold mix compositions as measured by the heights of the pill specimens.
  • Bituminous compositions of the present invention were produced and compacted using the procedure of Example 2.
  • Solvent-free bitumen emulsions were prepared using tallow polyalkylenepolyamine emulsifier at 0.5% by total weight of the bitumen emulsion (bwe).
  • the bitumen employed in this example was a commercially-available, performance-grade PG64-22 bitumen modified via the addition of styrene-butadiene-rubber (SBR). Two levels of bitumen modification were examined: 1% SBR bwe and 3% SBR bwe. All of the bituminous compositions in this example contained modified PG64-22 bitumen, and each was prepared with a bitumen content of 4.8% by total weight of the graded aggregate.
  • bituminous compositions were produced having equivalent aggregate gradation and bitumen content.
  • the procedure for the production of the bituminous composition of the present invention noted above was followed for producing these cold mix bituminous compositions with the exception that the bitumen emulsion and the graded aggregate were each at ambient room temperature (23° C.) when mixed in the bucket.
  • the pills made with the bituminous compositions of the present invention made at 1 % SBR bwe exhibited compressive strength values after curing at 25° C. for four hours which were over 220% higher than the identically formulated, emulsion-based cold mix bituminous compositions made and compacted at ambient laboratory conditions, while the pills made at 3% SBR bwe exhibited a 210% increase in compressive strength over the corresponding cold mix pills. Additionally, the bituminous compositions of the present invention showed substantially improved compaction compared to the analogous cold mix compositions as measured by the heights of the pill specimens.
  • Bituminous compositions of the present invention were produced and compacted using the procedure of Example 2.
  • Solvent-free bitumen emulsions were prepared using modified tall oil condensate of polyethylene polyamine at dosages ranging from 1.0% to 1.5% by total weight of the bitumen emulsion (bwe).
  • Three commercially-available, performance grade bitumen types were employed in this example: a PG64-22, a PG78-28, and a styrene-butadiene-styrene (SBS) modified PG64-22.
  • SBS styrene-butadiene-styrene
  • bitumen emulsion used in the evaluations shown in FIG. 2 , produced in Example 7 below, contains 1.0% bwe of emulsifier (modified tall oil fatty acid condensate of polyethylene polyamine).
  • bituminous compositions were produced having equivalent aggregate gradation and bitumen content.
  • the procedure for the production of the bituminous composition of the present invention noted above was followed for producing these cold mix bituminous compositions with the exception that the bitumen emulsion and the graded aggregate were each at ambient room temperature (23° C.) when mixed in the bucket.
  • the pills made with the bituminous compositions of the present invention exhibited compressive strength values after curing at 25° C. for four hours which were stronger than the identically formulated, emulsion-based cold mix bituminous compositions made and compacted at ambient laboratory conditions. Additionally, the bituminous compositions of the present invention showed improved compaction compared to the analogous cold mix compositions as measured by the heights of the pill specimens.
  • FIG. 2 shows comparable results using a different emulsion.
  • the bitumen emulsion used in the evaluations shown in FIG. 2 contained 1.0% bwe of emulsifier (modified tall oil fatty acid condensate of polyethylene polyamine) at 60% residue of PG64-22 bitumen (a performance-grade bitumen modified with a styrene-butadiene-styrene block copolymer).
  • emulsifier modified tall oil fatty acid condensate of polyethylene polyamine
  • PG64-22 bitumen a performance-grade bitumen modified with a styrene-butadiene-styrene block copolymer
  • Bituminous compositions of the present invention were produced and compacted using the procedure of Example 2.
  • Solvent-free bitumen emulsions were prepared using as an emulsifier modified and unmodified C16-C18 fatty acid condensate of polyethylene polyamine at dosages ranging from 1.0% to 1.5% by total weight of the bitumen emulsion (bwe).
  • Three commercially-available, performance grade bitumen types were employed in this example: a PG64-22, a PG70-22, and a styrene-butadiene-styrene (SBS) modified PG64-22.
  • SBS styrene-butadiene-styrene
  • bituminous compositions were produced having equivalent aggregate gradation and bitumen content.
  • the procedure for the production of the bituminous composition of the present invention noted above was followed for producing these cold mix bituminous compositions with the exception that the bitumen emulsion and the graded aggregate were each at ambient room temperature (23° C.) when mixed in the bucket.
  • the pills made with the bituminous compositions of the present invention exhibited compressive strength values after curing at 25° C. for four hours which were stronger than the identically formulated, emulsion-based cold mix bituminous compositions made and compacted at ambient laboratory conditions. Additionally, the bituminous compositions of the present invention showed substantially improved compaction compared to the analogous cold mix compositions as measured by the heights of the pill specimens.
  • FIG. 3 also shows comparable results in yet another differently formulated bitumen emulsion.
  • the bitumen emulsion used in the evaluations shown in FIG. 3 contained 0.75% bwe of emulsifier (modified and unmodified C16-C18 fatty acid condensate of polyethylene polyamine) at 60% residue of PG70-22 bitumen.
  • Bituminous compositions of the present invention were produced and compacted using the procedure of Example 2.
  • Solvent-free bitumen emulsions were prepared using alkyl quaternary amines emulsifier at 0.75% by total weight of the bitumen emulsion (bwe).
  • Three commercially-available, performance grade bitumen types were employed in this example: a PG64-22, a PG70-22, and a styrene-butadiene-styrene (SBS) modified PG64-22.
  • SBS styrene-butadiene-styrene
  • bituminous compositions were produced having equivalent aggregate gradation and bitumen content.
  • the procedure for the production of the bituminous composition of the present invention noted above was followed for producing these cold mix bituminous compositions with the exception that the bitumen emulsion and the graded aggregate were each at ambient room temperature (23° C.) when mixed in the bucket.
  • the pills made with the bituminous compositions of the present invention exhibited compressive strength values after curing at 25° C. for four hours which were stronger than the identically formulated, emulsion-based cold mix bituminous compositions made and compacted at ambient laboratory conditions. Additionally, the bituminous compositions of the present invention showed improved compaction compared to the analogous cold mix compositions as measured by the heights of the pill specimens.
  • Bituminous compositions of the present invention were produced and compacted using the procedure of Example 2.
  • Solvent-free bitumen emulsions were prepared using as an emulsifier a blend of tallow polyalkylenepolyamine and aminated natural resins from the general class known as quebracho resins at 1.5% by total weight of the bitumen emulsion (bwe).
  • Two commercially-available, performance grade bitumen types were employed in this example: a PG64-22 and a styrene-butadiene-styrene (SBS) modified PG64-22.
  • SBS styrene-butadiene-styrene
  • bituminous compositions were produced having equivalent aggregate gradation and bitumen content.
  • the procedure for the production of the bituminous composition of the present invention noted above was followed for producing these cold mix bituminous compositions with the exception that the bitumen emulsion and the graded aggregate were each at ambient room temperature (23° C.) when mixed in the bucket.
  • the pills made with the bituminous compositions of the present invention exhibited compressive strength values after curing at 25° C. for four hours which were stronger than the identically formulated, emulsion-based cold mix bituminous compositions made and compacted at ambient laboratory conditions. Additionally, the bituminous compositions of the present invention showed improved compaction compared to the analogous cold mix compositions as measured by the heights of the pill specimens.
  • a bituminous composition of the present invention was produced and compacted using the procedure of Example 2.
  • a solvent-free bitumen emulsion was prepared using as an emulsifier a blend of 0.2% by total weight of the bitumen emulsion (bwe) of tallow polyalkylenepolyamines and 0.8% bwe of polyethylenepolyamine condensate of modified and unmodified fatty acids.
  • the bitumen employed in this example was a commercially-available, performance-grade PG64-22 bitumen.
  • Each of the bituminous compositions in this example contained PG64-22 bitumen, and was prepared with a bitumen content of 4.8% by total weight of the graded aggregate.
  • bituminous composition having equivalent aggregate gradation and bitumen content.
  • the procedure for the production of the bituminous composition of the present invention noted above was followed for producing the cold mix bituminous composition with the exception that the bitumen emulsion and the graded aggregate were each at ambient room temperature (23° C.) when mixed in the bucket.
  • the pills made with the bituminous composition of the present invention exhibited a compressive strength value after curing at 25° C. for four hours which was stronger than the identically formulated, emulsion-based cold mix bituminous composition made and compacted at ambient laboratory conditions. Additionally, the bituminous composition of the present invention showed improved compaction compared to the analogous cold mix composition as measured by the heights of the pill specimens.
  • Bituminous compositions of the present invention were prepared by the following procedure. Solvent-free bitumen emulsions were prepared using tallow polyalkylenepolyamines emulsifier at 0.5% by total weight of the bitumen emulsion (bwe). The emulsifier was dissolved in warm water and treated with hydrochloric acid solution to lower the pH to 2.0. The aqueous solution of emulsifier(s) in water (called the “soap solution”) was heated to 55° C. and added to an Atomix colloid mill.
  • bitumen employed in this example was a commercially-available, performance-grade PG64-22.
  • the bitumen was heated to 130° C. and added to the Atomix colloid mill, wherein the soap solution and bitumen mixture was processed to produce bitumen emulsion.
  • the bitumen content of the finished bitumen emulsion was about 60-63% bwe.
  • the bitumen emulsions were subsequently diluted with water to 53.3% bitumen content prior to mixing with aggregate.
  • Example 1 The graded aggregate of Example 1 was heated to about 80° C. in an oven while the bitumen emulsion was heated to about 60° C. About 1,000 grams of heated graded aggregate were placed in a 1-gallon stainless steel bucket. To the 1,000 grams of aggregate at 80° C. was added 90 g of 60° C. bitumen emulsion. The mixture was stirred by hand for approximately 60 seconds to produce the bituminous compositions containing about 4.8% bitumen by total weight of the graded aggregate.
  • bitumen compositions having a temperature in the range of about 60° C. to about 80° C.
  • the bitumen compositions were then compacted using 30 gyrations of a SHRP Pine gyratory compactor at 600 kPa pressure and a gyration angle of 1.25°.
  • the compacted bituminous composition was subsequently placed in a 25° C. oven and allowed to cure for four hours. After four hours of curing, the physical and performance properties of the compacted and cured bituminous composition were measured.
  • the other resulting bitumen composition (having a temperature in the range of about 60° C. to about 80° C.) was immediately loaded and sealed in a polyethylene bag and placed in an oven having a temperature maintained at 60° C. After three hours, the bitumen composition (having a temperature of about 60° C.) was removed from the oven and immediately loaded into a 100-mm diameter gyratory compaction mold, which had been preheated to 60° C. The bitumen composition was then compacted using 30 gyrations of a SHRP Pine gyratory compactor at 600 kPa pressure and a gyration angle of 1.25°. The compacted bituminous composition was placed in a 25° C. oven and allowed to cure for four hours. After four hours of curing, the physical and performance properties of the compacted and cured bituminous composition were measured.
  • Bituminous compositions of the present invention were prepared by the following procedure. Solvent-free bitumen emulsions were prepared using tallow polyalkylenepolyamines emulsifier at 0.5% by total weight of the bitumen emulsion (bwe). The emulsifier was dissolved in warm water and treated with hydrochloric acid solution to lower the pH to 2.0. The aqueous solution of emulsifier(s) in water (called the “soap solution”) was heated to 55° C. and added to an Atomix colloid mill.
  • bitumen employed in this example was a commercially-available, performance-grade styrene-butadiene-styrene (SBS) modified PG64-22.
  • SBS performance-grade styrene-butadiene-styrene
  • the bitumen was heated to 130° C. and added to the Atomix colloid mill, wherein the soap solution and bitumen mixture was processed to produce bitumen emulsion.
  • the bitumen content of the finished bitumen emulsion was about 60-63% bwe.
  • the bitumen emulsions were subsequently diluted with water to 53.3% bitumen content prior to mixing with aggregate.
  • Example 1 The graded aggregate of Example 1 was heated to about 80° C. in an oven while the bitumen emulsion was heated to about 60° C. About 1,000 grams of heated graded aggregate were placed in a 1-gallon stainless steel bucket. To the 1,000 grams of aggregate at 80° C. was added 90 g of 60° C. bitumen emulsion. The mixture was stirred by hand for approximately 60 seconds to produce the bituminous compositions containing about 4.8% bitumen by total weight of the graded aggregate.
  • bitumen compositions having a temperature in the range of about 60° C. to about 80° C.
  • the bitumen compositions were then compacted using 30 gyrations of a SHRP Pine gyratory compactor at 600 kPa pressure and a gyration angle of 1.25°.
  • the compacted bituminous composition was subsequently placed in a 25° C. oven and allowed to cure for four hours. After four hours of curing, the physical and performance properties of the compacted and cured bituminous composition were measured.
  • the other resulting bitumen composition (having a temperature in the range of about 60° C. to about 80° C.) was immediately loaded into a polyethylene bag and placed in an oven having a temperature maintained at 60° C. After 21 hours, the bitumen composition (having a temperature of about 60° C.) was removed from the oven and immediately loaded into a 100-mm diameter gyratory compaction mold, which had been preheated to 60° C. The bitumen composition was then compacted using 30 gyrations of a SHRP Pine gyratory compactor at 600 kPa pressure and a gyration angle of 1.25°. The compacted bituminous composition was placed in a 25° C. oven and allowed to cure for four hours. After four hours of curing, the physical and performance properties of the compacted and cured bituminous composition were measured.
  • Solvent-free bitumen emulsions suitable for use in the production of bituminous compositions of the present invention were prepared by the following procedure.
  • a series of solvent-free bitumen emulsions were prepared using tallow polyalkylenepolyamines emulsifier at 1.0% by total weight of the bitumen emulsion (bwe).
  • the emulsifier was dissolved in warm water and treated with hydrochloric acid solution to lower the pH to 2.0.
  • the aqueous solution of emulsifier in water (called the “soap solution”) was heated to 55° C. and added to an Atomix colloid mill.
  • bitumen types were employed in this example in produce the series of bitumen emulsions.
  • a commercially available PG64-22 and a commercially available styrene-butadiene styrene (SBS) modified PG64-22 was used.
  • SBS styrene-butadiene styrene
  • a PG64-22 bitumen modified via the addition of styrene-butadiene-rubber (SBR) at either 1% SBR bwe or 3% SBR bwe were employed.
  • the respective bitumen were heated to 130° C. and added to the Atomix colloid mill, wherein the soap solution and bitumen mixture was processed to produce bitumen emulsion.
  • the resulting bitumen emulsions show substantially unchanged particle size distributions when held at elevated temperatures for a period of time.
  • Table XIII shows that with the unmodified bitumen the starting mean particle diameter (mv) was lower than in the case of the SBS-modified bitumen (Table XIV), as the SBS-modified bitumens give relatively high mean particle size diameters as well as high overall particle size distributions (as reflected in 90th percentile particle diameter).
  • TABLE XIII Particle Size Distribution At Elevated Temperature Time at Unmodified Bitumen Emulsion Indicated Storage Temperatures Temp. 25° C. 60° C. 80° C.
  • Bituminous compositions of the present invention were also produced in typical full-scale operations using parallel flow drum plants in full-scale construction projects conducted in the Republic of South Africa, where many new asphalt paving technologies have been developed in recent years.
  • solvent-free bitumen emulsions were prepared using 60/70 bitumen and emulsifiers consisting of blends of polyalkylenepolyamine condensate of modified and unmodified fatty acids and one or more tallow polyalkylenepolyamines.
  • Percentages of the polyalkylenepolyamine condensate of modified and unmodified fatty acids ranged from 0-1.0% and percentages of the tallow polyalkylenepolyamines ranged from 0-1.0%, both by weight of the emulsion.
  • the emulsifier was dissolved in warm water and treated with hydrochloric acid solution to lower the pH to 2.0.
  • the aqueous solution of emulsifier(s) in water (called the “soap solution”) was heated to 55° C. and added to an Atomix-type colloid mills. Aggregate was a 9.5 mm nominal andesite with mine tailings.
  • the P-200 content in the aggregate was 7.5%.
  • Emulsion was diluted to 50% bitumen residue prior to injection into a parallel drum plant. Sufficient emulsion was pumped into the drum mixer to yield a bituminous composition having 5.4% bitumen by weight of the aggregate. No dust was emitted from the dust collector on the drum mixer during the course of full-scale production of the bituminous composition.
  • the temperature of samples of the production-scale bituminous composition according to this invention ranged between 80-120° C.
  • the bituminous mixture was stored in a conventional, unheated hot-mix asphalt storage silo. After roughly eighteen hours of silo storage, the bituminous composition was discharged to standard 15-ton dump trucks.
  • Bituminous compositions of the present invention were also produced on a manufacturing scale in parallel flow drum plants in a second field project the Republic of South Africa, where many new asphalt paving technologies have been developed.
  • solvent-free bitumen emulsions were prepared using 80/100 bitumen and emulsifiers consisting of blends of polyalkylenepolyamine condensate of modified and unmodified fatty acids and one or more tallow polyalkylenepolyamines. Percentages of the polyalkylenepolyamine condensate of modified and unmodified fatty acids ranged from 0-0.30% and percentages of the tallow polyalkylenepolyamines ranged from 0-0.30%, both by weight of the emulsion.
  • the emulsifier was dissolved in warm water and treated with hydrochloric acid solution to lower the pH to 2.0.
  • the aqueous solution of emulsifier(s) in water (called the “soap solution”) was heated to 55° C. and added to an Atomix-type colloid mills. Aggregate was a 19-mm nominal basalt. The P-200 content in the aggregate was roughly 7.0%. Emulsion was produced at 68% bitumen residue. Sufficient emulsion was pumped into the drum mixer to yield a bituminous composition having 5.0% bitumen by weight of the aggregate. No dust was emitted from the dust collector on the drum mixer during the course of full-scale production of the bituminous composition.
  • the temperature of samples of the production-scale bituminous composition according to this invention ranged between 60-120° C.
  • the bituminous mixture was stored briefly in a conventional, unheated hot-mix asphalt storage silo before being metered to standard 15-ton dump trucks.
  • the trucks discharged the mixture to a standard hot mix paver, which distributed the mix in depths of 0.75 to 2 inches and widths of eight to ten feet wide, according to standard lay-down construction practices. No sticking of the bituminous composition was observed in the beds of the dump trucks or in the moving parts or screed of the hot-mix paver.
  • a tandem steel wheel roller (13-ton) was used as break-down compacters, followed by pneumatic rollers (20-ton) for finishing compaction.

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US11/457,931 US20070039520A1 (en) 2004-02-18 2006-07-17 Method for producing bituminous compositions
US11/862,273 US7905949B2 (en) 2004-02-18 2007-09-27 Method for producing bituminous compositions
US12/905,886 US7972429B2 (en) 2004-02-18 2010-10-15 Bituminous composition
US13/116,517 US8088210B2 (en) 2004-02-18 2011-05-26 Bituminous composition
US13/309,622 US8444760B2 (en) 2004-02-18 2011-12-02 Bituminous composition
US13/866,166 US9260608B2 (en) 2004-02-18 2013-04-19 Bituminous composition

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