WO2020105020A1

WO2020105020A1 - Bitumen packaging container for preservation and transportation with dissolution capability

Info

Publication number: WO2020105020A1
Application number: PCT/IB2019/061254
Authority: WO
Inventors: Aliakbar KAZEMAINI
Original assignee: Kazemaini Aliakbar
Priority date: 2018-11-19
Filing date: 2019-12-22
Publication date: 2020-05-28

Abstract

Modified bitumen packaging method for storage and transportation: Unlike other methods in which polymeric additives are added to the bitumen penetration grade 60/70, the bitumen is modified, produced and then packaged. In this method, using a certain percentage of the polymer which is to be added to the bitumen, a packaging container with certain characteristics is produced and the bitumen is packed into it. At destination, the packaged bitumen (with its container) is placed into the curing pot and modified bitumen shall be ready for use. Using modified bitumen packaging method, the need for packaging container or wrapper is eliminated and the bitumen can be palletized, containerized and transported in the usual commercial way

Description

Bitumen packaging container for preservation and transportation with dissolution capability

This statement is filed and provided based on a local statement, at IRIPO's Intellectual Property Center No.: 139750140003007128 in 2018 November 19.

This invention is related to various fields such as chemistry, polymer chemistry and packaging industry.

Modified bitumen generally has a high softening point and its permeability rate is low due to the existence of modifying polymers. It is very similar to the so-called hard bitumen in the market

For a long time, this bitumen was packed in metal barrels or cylindrical cartons, which in addition to their high packaging costs were difficult and costly to use and always resulted in packaging wastes. In the recent years, this bitumen has been packed in new forms as heat-resistant polymer bags, either in multilayer bags or into cellulose cartons or paper wrappers. This type of packaging has the following disadvantages:

Creating packaging waste and rubbish

Formulation quality change, as heat-resistant polymers (polyamide) together with packaging bitumen in it enter the curing pot.

Modified bitumen should be packed at high temperatures due to their high softening point; therefore, packaging risks shall be very high.

High water consumption for cooling purposes.

In commercial transportations via standard international containers volume/weight balance should be followed which is an impossible requirement with most common packaging systems. Some of the searched samples with some differences are as follows:

US5992628 - Asphalt packages with consumable containers

US2016355296 - Systems and methods for providing a packaged thermoplastic material

In the above-mentioned patents: 1) The dimensions cited in the drawings do not correspond with transportation standards. Moreover, the container’s final weight makes it too heavy for having transportation capabilities. By the way, layout / number arrangement is not possible. 2) For the idea claimed here a lid has been devised with the capability of packaging soft bitumen (with low softening point) whereas, in the patent mentioned above, there is no possibility for packaging soft bitumen and only hard bitumen (with high softening point) can be packed.

In the text of the patent references have been made to hard bitumen with the softening points between 85 to 96, and bitumen with high softening points due to high percentage of Asphaltenes and lower percentage of Maltin have lower polymer reception capability and bitumen with low softening points have better performance.

The packaging type and form, designed in the invention claimed, shall be the same polymer used to modify the bitumen and form the packaging container. Therefore, there will be no need for high heating and water consumption for cooling.

Since the claimed invention is proposed for packaging bitumen with low softening point, therefore, the bitumen temperature in flux state at the time of packing will be about 80ºC which in the above-mentioned patent reaches to 150ºC and to prevent the container’s polymer wall from slackening, the outer wall needs to be cooled down with water. But in the new design this is eliminated.

Materials such as PP, EVA and PE have been suggested for manufacturing the container, and to produce softness inside container’s polymer a type of vax has been offered.

But since the new container has a higher weight and thickness and contains all the polymers required for the formulation of polymer bitumen, it can be produced with APP, APAO, EPDM, SBR compounds and the like, capable of tolerating bitumen’s weight. In the claimed new invention, the final weight of the full and empty containers has been determined to be 20 kg and 4 kg respectively making up about 20% of the total weight of the final polymer bitumen. In general, the problems of current patents and products are summarized below:

High cost of materials needed in packaging: barrel metal sheet, carton, paper, polymer bag, sachet.

Production of packaging wastes: metal scrap, cellulose scrap, polymer scrap.

Formulation changes: In most cases polymer packages with bitumen pour into the tanks which cannot be calculated.

High shipping cost: Except for basic materials, shipping costs shall be paid for barrel metal and similar packaging materials, or if in bulk, the cost of heating and warm keeping should be paid.

Difficult storage conditions: Storing barrels or ordinary packages requires a lot of space and special storage conditions and bulk storage must be carried out using large tanks with insulation and heating system.

Low packing speed: Due to the high bitumen temperature at the time of packaging, the packaging process is slow and it takes a long time for the bitumen to cool down which reduces the packaging speed.

Special Packaging Conditions: As bitumen softening point increases, the packaging conditions become more difficult and dangerous.

High Water Consumption: In order to cool containers, water is generally used as a pool or spray.

Modified bitumen packaging method for storage and transportation: Unlike other methods in which polymeric additives are added to the bitumen penetration grade 60/70, the bitumen is modified, produced and then packaged. In this method, using a certain percentage of the polymer which is to be added to the bitumen, a packaging container with certain characteristics is produced and the bitumen is packed into it. At destination, the packaged bitumen (with its container) is placed into the curing pot and modified bitumen shall be ready for use. Using modified bitumen packaging method, the need for packaging container or wrapper is eliminated and the bitumen can be palletized, containerized and transported in the usual commercial way. For this purpose, the formula for the bitumen and polymer is calculated as the percentage of polymer in the weight of the container and 60/70 percent of the volume of the container. The net weight for each container will be 20 kg despite its external volume of 30 liters. The dimensions shall be 50 cm long, 25 cm wide and 20 cm high with the lid of the container, placed in 8 rows of 8 on 110 × 110 cm pallets, and 22 pallets with such dimensions covers all weight and volume capacity of a 40-foot container in accordance with international standards.

There are various methods for storing and handling bitumen, such as bulk, metal barrels, polymer bags, paper and cardboard bags, jumbo bags, and polymer flasks, but these have disadvantages as outlined below:

The need to keep the bitumen warm

Reheating the bitumen for discharge

High shipping cost due to returning empty containers to their departure point.

Restrictions on purchase, consumption and transfer in small quantities

Cost of packaging materials

Obligatory transportation of the material in addition to the bitumen due to packaging

Formula control restrictions for the addition of bitumen packaging materials

Bitumen wastes due to adhesion to the packaging materials.

Packing containers cannot be laid on each other to fill up large areas of waste (packaging materials such as barrel sheets and cartons paid for their purchase and shipment).

Low packaging speed due to the high temperature of the modified bitumen and high water consumption

Introducing a fast, cheap, easy and practical method for packaging modified bitumen and creating added value for the export and sale of modified bitumen instead of raw bitumen, as well as easy access of bitumen-consuming workshops to modified bitumen and improving the quality of bitumen products and fixing the problems mentioned above are among the goals of this innovative method for packaging modified bitumen. Using modified bitumen packaging method, the need for packaging container or wrapper is eliminated and the packaged bitumen can be palletized, containerized and transported in the usual commercial way.

Bitumen packaging container, used for preservation and transportation with dissolution capability, is a container for packaging bitumen without the need for separation from the container. To modify bitumen at normal conditions and especially increasing bitumen softening point P.P and P.E polymers are used and to modify bitumen at standard conditions especially for wet insulation, polymeric compound is used in accordance with the declaration No. 139750140003004467 filed at IRIPO, Iran Intellectual Property Center, on August 16, 2018 and in all these methods the polymeric additive is added to bitumen penetration grade 60/70. In the modified bitumen packaging method for preservation and transportation, instead of adding polymers to the bitumen and producing modified bitumen and finally packaging it, a packaging container with certain characteristics is prepared with a certain percentage of the polymer to be added and the bitumen penetration grade 60/70 is packed into it and then, at the destination, the packaged bitumen is placed into the curing pot and the modified bitumen shall be ready for use. Using this method, the need for packaging container or wrapper is eliminated and the packaged bitumen can be palletized, containerized and transported in the usual commercial way. To accomplish this, the formula for the bitumen and polymer is premeditated as the percentage of polymer in the weight of the container and 60/70 percent of the volume of the container. The net weight for each container will be 20 kg despite its external volume of 30 liters. The dimensions shall be 50 cm long, 25 cm wide and 20 cm high with the lid of the container, placed in 8 rows of 8 on 110 × 110 cm pallets, and 22 pallets with such dimensions covers all weight and volume capacity of a 40-foot container in accordance with international standards. Using modified bitumen packaging method for preservation and transportation:

Full elimination of packaging material costs

Full elimination of packaging material wastes

Same bitumen formula

Reduced shipping costs

Easy and economical storage conditions

High speed of packaging

No specific packaging requirements

No need for water in cooling

Full elimination of packaging material costs: Because packaging materials are part of material formula and no other packaging materials are used.

Full elimination of packaging material wastes: No wastes shall be produced since no packaging materials are used.

Same bitumen formula: Because the polymer-to-bitumen ratio has already been calculated in container production, then modified bitumen shall always be produced uniformly.

Reduced shipping costs: Since packaging materials such as barrels are not used, therefore there is no need to carry excess materials such as metal barrels, and concerning bulk shipment, since there is no need for using tankers, and the shipment is carried out commercially the shipment cost is halved because there shall be no need for the empty bitumen tanker to return.

Easy and economical storage conditions: The new layout of packaged bitumen is designed to be up to 3 meters high with no empty spaces in between, and like bulk storage there shall be no need for strong, insulated tanks with heating capability.

High speed of packaging: Due to the low temperature of bitumen at the time of packaging and the mechanization of packaging system of containers, this method shall be of high speed and safety.

Specific packaging conditions: Given that the packaged bitumen is penetration 60/70 grade bitumen with a softening point of 50 ºC, the packaging temperature shall be between 80 and 100 ºC. Moreover, the thickness of the polymer container wall which is proportional to the formula weight is of the right thickness and unlike traditional methods requires no special packaging requirements.

No need for water in cooling: The whole operating temperature of the process shall not be higher than 100 ºC and no cooling shall be needed. Also, the container shall be cooled with more speed due to its special design.

As shown in the attached drawings, the proposed packaging container has two body parts and a lid, both of which can be manufactured by a 3-kg plastic injection machine. Simply, mix the raw materials manually, including PP-PE-EVA-APP-APAO-SBR and the softeners and stabilizers according to the ordered formula, or prepare the raw materials of the modifying compound and then feed into the feeding funnel. And after installation of the mold and machine start up, the packaging container is produced. The type of material to produce depends on the purpose of bitumen modification. For example, for the manufacture of polymer asphalt, bitumen for repairing asphalt cracks, producing mastic for parting (discontinuity) joints, the production of moisture insulating materials or the like, each of which must be prepared according to the formula provided by the customer or recommended by the container manufacturer. However, in any case, PP or PE content in the polymer produced shall not be under 30%. The formula refers to the composition of the polymer from which the container is produced. Once the container is filled with bitumen in the final curing pot, it is combined with the bitumen in the container and the modified bitumen is produced.

The color of the container produced shall be different depending on the type of polymer used which can be painted with dark master batches. For example, different types of products can be introduced in a variety of colors, but considering the black color of bitumen, black color seems more appropriate.

On both sides of the container in the longitudinal direction as well as on the lid, there is enough space for labeling or printing on the container for showing material type, usage, instructions as well as logo, brand and address.

The container body is designed in a way to allow for retailing of modified bitumen. In case amounts less than 20 kg are required, it is possible to divide a container into 4 parts of 5 kg and offer the product in 5 kg parts. It is generally used for roof or asphalt insulation repairs, car parts coatings, connecting high-pressure cables, repairing bitumen coatings of pipes and so on requiring modified bitumen.

To pack the bitumen into new containers, we need a hot bitumen tank storing soft bitumen (bitumen with low softening point such as 60/70 or 80/100) from 80 ºC to 100 ºC in flux state and to set up the packaging line in front of the tank. Packaging line consists of two parts of filling and conveyer system. The conveyer system is comprised of a moving chain with a special form which shouldn’t be less than 60 cm in width (for two rows of containers) on which empty containers are placed without lids. The chain, after passing under filling part moves the filled and hot containers forward for about 20 m and in the end, when the lids are fitted on the containers using a rubber hammer, the containers are transferred into the pallets. The filling part can also be manual or automatic. In automatic mode, the hot bitumen is pumped into the metal cylinders, and after the electronic eye commands that the empty container under the solenoid valve is ready to be filled, the cylinder is emptied into the container by the pressure from the piston. In the manual mode, the container valves are manually opened and closed by manpower.

Fig.1

Cross-section cutting of modified bitumen container for storage and transportation

Fig.2

Modified bitumen packaging container for storage and transportation without lid

Fig.3

Modified bitumen container lid for storage and transportation

Fig.4

Bottom view of modified bitumen container for storage and transportation

Fig.5

Single pallet for modified bitumen container for storage and transportation

Fig.6

How to seal a modified bitumen container for storage and transportation

Fig.7

Longitudinal cutting of modified bitumen container for storage and transportation

Examples

Bitumen packaging container for preservation and transportation with dissolution capability, at the destination, the bitumen along with the container is poured into the curing pot and the modified bitumen becomes ready for consumption.

Bitumen packaging container for preservation and transportation with dissolution capability is a container for packaging bitumen. Considering the wide range of production and consumption of modified bitumen, manufacturing containers with different formulas fulfills a high volume of bitumen consumptions such as road construction, road asphalt repairs, prefabricated waterproofing materials, hot bitumen coatings, moisture insulating works, electronics and electrical industries, automobile industries, high-pressure cables, rubber parts manufacturing, handicrafts and dozens of other industries related to modified bitumen. Moreover, in case packaging of bitumen without modification is required, various types of bitumen could be produced in plain containers from PP or PE materials without any formulations. High weights of containers are not, then, needed any longer and low weights are possible too. The only thing to do is replacing containers’ lids immediately after filling and cooling them with water spray, since the weight of the container is related to the main formula only at times when bitumen modification is being carried out.

Claims

Bitumen packaging container for preservation and transportation with dissolution capability, unlike other methods in which polymer additives are added to the bitumen penetration grade 60/70, in this process modified bitumen is produced and a special packaging container is made with a certain percentage of the polymer to be added to the bitumen. The 70/60 bitumen is then packed inside it and then poured into the curing pot at the destination along with the container and the modified bitumen shall be ready for consumption.
According claim 1; The formulaic proportion of bitumen and polymer is calculated by considering the percentage of polymer in the weight of the container and the percentage of 60/70 in the container volume.
According claim 1; The net weight of each container shall be 20 kg, despite its 30 liters’ external volume.
According claim 3; The proposed packaging container has two body parts and a lid that can both be manufactured by a 3-kg plastic injection machine.
According claim 4; The raw materials include PP-PE-EVA-APP-APAO-SBR and the softeners and stabilizers which are manually mixed according to the ordered formula and then fed into the feeding funnel of the injection machine, and after the installation of the mold and machine start up, the packaging container is produced.
According claim 1; The type of material to produce depends on the purpose of bitumen modification. For example, for the manufacture of polymer asphalt, bitumen for repairing asphalt cracks, producing mastic for separation (discontinuity) joints, the production of moisture insulation materials, or the like, each of which must be prepared according to the formula. The formula can be provided by the customer or recommended by the container manufacturer. However, in any case, PP or PE content in the polymer produced shall not be less than 30%.
According claim 5; Packaging container dimensions: Length 50 cm, width 25 cm and height 20 cm.
According claim 5; The container with its lid shall be placed in 8 rows of 8 on 110 × 110 cm pallets and 22 pallets with such dimensions covers all weight and volume capacity of a 40-foot container in accordance with international standards.
According claim 1; The color of the container produced shall be different depending on the type of polymer used which can be painted with dark master batches. For example, different types of products can be introduced in a variety of colors, but considering the black color of bitumen, black color seems more appropriate.
According claim 1; On both sides of the container in the longitudinal direction as well as on the lid, there is enough space for labeling or printing on the container for showing material type, usage, instructions as well as the logo, brand and address.
According claim 5; The container body is designed in a way to allow for retailing of modified bitumen. In case amounts less than 20 kg are required, it is possible to divide a container into 4 parts of 5 kg and offer the product in 5 kg parts.
According claim 1; To pack the bitumen into new containers, we need a hot bitumen tank storing soft bitumen (bitumen with low softening point such as 60/70 or 80/100) from 80 ºC to 100 ºC in flux state and to set up the packaging line in front of the tank.
According claim 12; The Packaging line consists of two parts of filling and conveyer system. The conveyer system comprised of a chain with a special form which shouldn’t be less than 60 cm in width (for two rows of containers) moves and empty containers are placed on it without lids. The chain, after passing under filling part moves the filled and hot containers forward for about 20 m and in the end, when the lids are fitted on the containers using a rubber hammer, the containers are transferred into the pallets.
According claim 12; The filling part can also be manual or automatic. In automatic mode, hot bitumen is pumped into the metal cylinders, and after the electronic eye commands that the empty container under the solenoid valve is ready to be filled, the cylinder is emptied into the container by the pressure from the piston. In the manual mode, the container valves are manually opened and closed by manpower.