Systems, methods, and apparatus for recycling asphalt shingles

Abstract

A method for recycling asphalt shingles is provided, where the method includes heating an asphalt shingles input from a first source in a mixing unit to melt the asphalt shingles input and produce molten asphalt, directing the molten asphalt into a separation unit, separating the molten asphalt into a solid material and a fluid asphalt in the separation unit, and recycling the solid material from the fluid asphalt. And receive and store the fluid pitch in the storage tank. Separation units and systems for reusing asphalt shingles are also disclosed.

Description

Technical Field

[0001] The present disclosure relates to reusing asphalt shingles. More particularly, the present disclosure relates to systems, methods, and apparatus for reusing asphalt shingles. Background Art

[0002] Certain embodiments of asphalt shingles are formed from asphalt. During roof replacement, asphalt shingles may be removed. The removed asphalt shingles may be discarded. More preferably, the asphalt shingles may be reused. For example, the reused asphalt shingles may be reused to form asphalt pavement. However, certain existing embodiments of methods for reusing asphalt shingles may result in material waste (e.g., large pieces of asphalt shingles and / or fluid asphalt) that cannot be used to produce reused asphalt pavement and typically end up in a landfill. Therefore, it is desirable to reuse this material waste to avoid causing landfill. Summary of the Invention

[0003]

[0014] Embodiments of the present disclosure relate to reusing asphalt shingles.

[0004] Example embodiment 1: A method for reusing asphalt shingles, the method comprising: heating an asphalt shingle input from a first source in a mixing unit to melt the asphalt shingle input and produce molten asphalt; directing the molten asphalt to a separation unit; separating the molten asphalt into solid material and fluid asphalt in the separation unit; and, receiving and storing the fluid asphalt in a storage tank.

[0005] Example embodiment 2: The method according to example embodiment 1, or any combination of the foregoing example embodiments, further includes directing a first amount of fluid asphalt from the separation unit to a storage tank, and directing a second amount of fluid asphalt from the separation unit to a mixing unit or directing a certain amount of raw fluid asphalt from a raw fluid asphalt source to the mixing unit.

[0006] Example Embodiment 3: The method of Example Embodiment 2, or any combination of the preceding Example Embodiments, further comprising mixing a second amount of fluid asphalt with the asphalt shingle input in a mixing unit and heating to produce molten asphalt.

[0007] Example Embodiment 4: The method of Example Embodiment 1, or any combination of the preceding Example Embodiments, further comprising milling a plurality of asphalt shingles to produce an asphalt shingle input.

[0008] Example embodiment 5: The method according to example embodiment 1, or any combination of the preceding example embodiments, further comprising stirring the molten asphalt in the mixing unit by at least one circulation blade disposed in the mixing unit.

[0009] Example Embodiment 6: The method of Example Embodiment 1, or any combination of the preceding Example Embodiments, further comprising directing the solid material into a transportable container disposed downstream of the separation unit.

[0010] Example embodiment 7: The method according to example embodiment 1, or any combination of the foregoing example embodiments, wherein the separation unit comprises an inverted cone having an inner diameter toward its top portion that is greater than an inner diameter toward its bottom portion, and wherein separating the molten asphalt into solid material and fluid asphalt comprises allowing the solid material to settle toward the bottom portion of the separation unit and allowing the fluid asphalt to remain toward the top portion of the separation unit.

[0011] Example embodiment 8: A separation unit comprises: a tank defining an inverted cone having an inner diameter toward its top portion that is larger than the inner diameter toward its bottom portion; an inlet port connected to the tank and configured to receive molten asphalt; a first outlet port connected toward the top portion of the tank and configured to output fluid asphalt separated from solid matter in the molten asphalt; a second outlet port connected at the bottom portion of the tank and configured to output solid matter settled toward the bottom portion of the tank; and a heating mechanism configured to heat the molten asphalt in the tank.

[0012] Example embodiment 9: The separation unit according to example embodiment 8, or any combination of the foregoing example embodiments, further includes a third outlet port connected to the tank between the first outlet port and the second outlet port, wherein the first outlet port is configured to output a first amount of fluid asphalt to the storage tank, and wherein the mixing unit is configured to receive a second amount of fluid asphalt output from the third outlet port or a certain amount of raw fluid asphalt output from the raw fluid asphalt source.

[0013] Example Embodiment 10: The separation unit according to Example Embodiment 8, or any combination of the preceding Example Embodiments, further comprising a valve disposed at the second outlet port and configured to selectively direct solid material therethrough.

[0014] Example Embodiment 11: The separation unit according to Example Embodiment 8, or any combination of the preceding Example Embodiments, further comprising a pump located downstream of the first outlet port.

[0015] Example embodiment 12: The separation unit of example embodiment 8, or any combination of the foregoing example embodiments, wherein the tank comprises an inner surface in contact with the molten asphalt and an outer surface with a chamber defined therebetween, and the heating mechanism comprises a quantity of heating oil circulating in the chamber of the tank to maintain the temperature of the molten asphalt in the tank at about 250 degrees Fahrenheit to about 350 degrees Fahrenheit.

[0016] Example embodiment 13: A system for reusing asphalt shingles, the system comprising: a mixing unit arranged to receive an asphalt shingle input from a first source, the mixing unit configured to heat and melt the asphalt shingle input and produce molten asphalt; a separation unit arranged to receive the molten asphalt and separate the molten asphalt into solid material and fluid asphalt; and a storage tank configured to receive and store the fluid asphalt output from the separation unit.

[0017] Example Embodiment 14: The system of Example Embodiment 13, or any combination of the preceding Example Embodiments, further comprising a grinder configured to grind the plurality of asphalt shingles to produce the asphalt shingle input.

[0018] Example Embodiment 15: The system of Example Embodiment 13, or any combination of the preceding Example Embodiments, further comprising at least one circulation blade disposed in the mixing unit to stir the molten asphalt in the mixing unit.

[0019] Example embodiment 16: A system according to example embodiment 13, or any combination of the foregoing example embodiments, wherein the separation unit comprises: a tank defining an inverted conical shape having an inner diameter toward its top portion that is greater than an inner diameter toward its bottom portion; an inlet port connected to the tank and configured to receive molten asphalt; a first outlet port connected toward the top portion of the tank and configured to output fluid asphalt separated from solid material of the molten asphalt to a storage tank; a second outlet port connected at the bottom portion of the tank and configured to output solid material that has settled toward the bottom portion of the tank; and a heating mechanism configured to heat the molten asphalt in the tank.

[0020] Example embodiment 17: A system according to example embodiment 16, or any combination of the foregoing example embodiments, wherein the separation unit further includes a third outlet port connected between the first outlet port and the second outlet port, wherein the first outlet port is configured to output a first amount of fluid asphalt to a storage tank, and wherein the mixing unit is configured to receive a second amount of fluid asphalt output from the third outlet port or raw fluid asphalt output from the raw fluid asphalt source.

[0021] Example Embodiment 18: The system of Example Embodiment 17, or any combination of the preceding Example Embodiments, wherein the mixing unit is configured to mix and heat the second amount of fluid asphalt with the asphalt shingle input to produce molten asphalt.

[0022] Example Embodiment 19: The system of Example Embodiment 17, or any combination of the preceding Example Embodiments, further comprising a transportable container positioned adjacent the second outlet port of the separation unit and configured to collect solid material that settles toward the bottom portion of the tank.

[0023] Example embodiment 20: A system according to example embodiment 17, or any combination of the foregoing example embodiments, wherein the tank of the separation unit includes an inner surface in contact with the molten asphalt and an outer surface with a chamber defined therebetween, and the heating mechanism includes a quantity of heating oil circulating in the chamber of the tank to maintain the temperature of the molten asphalt in the tank at about 250 degrees Fahrenheit to about 350 degrees Fahrenheit.

[0024] These and other features, aspects, and advantages of the present disclosure will be more clearly understood from a reading of the following detailed description taken in conjunction with the accompanying drawings described hereinafter. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] To assist in understanding the embodiments of the present disclosure, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. The drawings are merely exemplary and should not be construed as limiting the present disclosure.

[0026] Figure 1 schematically illustrates a system for reusing asphalt shingles according to a first example embodiment of the present disclosure;

[0027] Figure 2 schematically illustrates a system for reusing asphalt shingles according to a second example embodiment of the present disclosure;

[0028] Figure 3 schematically illustrates a controller of a system for reusing asphalt shingles according to some example embodiments of the present disclosure; and

[0029] Figure 4 Methods for reusing asphalt shingles according to some example embodiments of the present disclosure are schematically illustrated. DETAILED DESCRIPTION

[0030] The present disclosure will be described more fully below with reference to the accompanying drawings. The present disclosure can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that the present disclosure will satisfy applicable legal requirements. Like reference numerals refer to like elements throughout. As used in this specification and claims, the singular forms "a," "an," and "the" include plural references unless the context clearly indicates otherwise.

[0031] As described herein, embodiments of the present disclosure relate to separating fluid asphalt and solid materials (e.g., sand, crushed aggregate, or gravel) from recycled asphalt shingles for secondary uses, such as, for example, the sand, crushed aggregate, or gravel can be used in asphalt applications, such as road applications. In this regard, Figure 1A first embodiment of a system 100 for recycling asphalt shingles to produce fluid asphalt and solid material is shown. System 100 can be controlled by a controller 102 configured to control some or all of the operations described below. In some embodiments, controller 102 can include a programmable logic controller. It should be noted that while controller 102 is shown as a single, integral device, in some embodiments, the controller can be distributed across multiple independent devices, which can individually or jointly control the operation of various portions of system 100. Figure 3 An example implementation of a controller is described in more detail in .

[0032] like Figure 1 As shown in , the system 100 may further include one or more mixing units. For example, the system 100 may include a primary mixing unit and a main mixing unit, performing different functions within the system. However, as Figure 1 As shown in FIG, system 100 includes a single mixing unit 104 (eg, a drum mixer), although it is contemplated by the present disclosure that more than one mixing unit may be used.

[0033] Mixing unit 104 may include a tank 105 configured to mix and / or heat one or more inputs (e.g., one input, two inputs, three inputs, four inputs, five inputs, etc.). In some embodiments, mixing unit 104 can be used for conventional asphalt mixing production by combining a fluid asphalt input with a pellet input. It should be noted that while the following describes the use of a single input, a greater number of inputs of the same or different types may be employed in other embodiments. Mixing unit 104 may further include one or more load cells (not shown). The load cells can be used to determine the individual mass of one or more inputs directed to mixing unit 104, thereby enabling proper mixing. Furthermore, mixing unit 104 may be configured to heat the inputs. For example, mixing unit 104 may include a heater 106, such as a coil, a burner, a boiler, a circulating hot fluid (e.g., oil or steam) around tank 105, and heaters that heat and / or dry the various inputs directed to mixing unit 104. In this way, mixing unit 104 ideally minimizes the moisture content of its contents.

[0034] Mixing unit 104 can be configured to receive asphalt shingle input 107 from a first source 108. Asphalt shingle input 107 can be in a plurality of solid forms, rather than in a liquid form. Asphalt shingle input 107 can include used asphalt shingles, scrap or waste from the asphalt shingle production process, or any other embodiment of asphalt shingles. The asphalt shingles and scrap can be ground or otherwise processed in a grinder 109 to produce relatively small-sized asphalt shingles for use as asphalt shingle input 107. Furthermore, during processing, nails and other debris can be removed from the asphalt shingles to produce asphalt shingle input 107.

[0035] In some example embodiments, the grinder 109 may crush or grind the asphalt shingles to a desired particle size (e.g., a maximum size of about 1 / 8" to about 1", and preferably a maximum size of about 1 / 4" to about 3 / 8"), cleaned of nails and other debris, and stockpiled as needed based on production volume and availability to meet agency specifications. The processed asphalt shingle input 107 is typically stored in an inventory on the mixing plant site, in a well-drained area and / or covered to minimize moisture content. Prior to use in mix production, the inventory of asphalt shingle input 107 may be tested for residual asphalt content, aggregate grading, and moisture content. The asphalt shingle input 107 may be delivered to a feed system, i.e., a first source 108, by a loader or other piece of equipment. The feed system (and any other equipment described herein) may be interlocked with other plant components and controlled by the controller 102. The feed system 108 may include a feed hopper 110 that may be equipped with a variable frequency drive (VFD) motor, a filter (e.g., including one or more screens), and one or more conveyors 111 (e.g., including an augers). Under the control of the controller 102, the feed system may be calibrated to adjust the flow rate of the asphalt shingle input 107 to the mixing unit 104, and may take into account moisture content, residual asphalt content, mixture yield, and the percentage of the total asphalt mixture defined by the asphalt shingle input.

[0036] Various other inputs may also be mixed with the asphalt shingle input 107 in the mixing unit 104. For example, the mixing unit 104 may be configured to receive a fluid asphalt input. The fluid asphalt input may be a recycled fluid asphalt input (i.e., the second amount of fluid asphalt input 112), or it may be a raw fluid asphalt input directed to the mixing unit 104 from a raw fluid asphalt source (not shown). The fluid asphalt input, also known as bitumen, is a black, highly viscous fluid in the form of petroleum. Alternatively, in some example embodiments, the mixing unit 104 may be configured to receive a granular input (not shown) from a granular source (not shown). The granular input may include a degree of moisture (e.g., due to being stored outdoors), which may be reduced by the heater 106. The granular input may include sand, gravel, crushed stone, slag, recycled concrete, aggregate (geosynthetic aggregate), and / or any other granular material. In some embodiments, it may be desirable to use recycled materials in the production of asphalt. In this regard, certain asphalt-containing materials may be reused in the system 100. Thus, for example, in some embodiments, a recycled asphalt input (not shown) may be directed to the mixing unit 104. The recycled asphalt input may include recycled asphalt pavement.

[0037] When the asphalt shingle input 107 is received into the mixing unit 104, the heater 106 of the mixing unit 104 can heat the asphalt shingle input 107 and can completely or substantially completely melt the asphalt shingle input 107 to produce molten asphalt 113, which is then directed to the separation unit 114. The temperature in the mixing unit 104 can be adjusted (e.g., as managed by the controller 102 via the heater 106) to maintain a desired temperature, generally between 250 and 450 degrees Fahrenheit, depending on the type and grade of asphalt shingle input 107 used. For example, the tank 105 of the mixing unit 104 can be heated by the heater 106 to heat the molten asphalt 113 to a temperature of approximately 250 degrees Fahrenheit to approximately 350 degrees Fahrenheit, desirably 400 degrees Fahrenheit, in order to maintain the molten asphalt 113 in a fluid form during transportation and during the direction to the separation unit 114, thereby avoiding issues with resolidification of the asphalt from the shingles.

[0038] As the asphalt shingle input 107 melts within the tank 105 of the mixing unit 104 to form molten asphalt 113, it is continuously stirred by at least one circulating blade disposed in the mixing unit 104, thereby removing moisture from the asphalt shingle input 107, activating residual asphalt, and preventing solid precipitation from the melted asphalt shingle input 107. In this way, as Figure 1As shown in FIG, a first circulation blade 115a and a second circulation blade 115b may be arranged in the mixing unit 104. The first circulation blade 115a may be arranged vertically above the second circulation blade 115b in the trough 105, and the second circulation blade 115b may be arranged toward the bottom of the trough 105 of the mixing unit 104. Other types of mixers may also be used alone or in combination with at least one circulation blade in the mixing unit 104.

[0039] In some exemplary embodiments, mixing unit 104 includes an outlet port 116 disposed toward the bottom of tank 105 of mixing unit 104 and adjacent to second circulating blade 115b. Molten asphalt 113 may be directed through outlet port 116 to separation unit 114. One or more heated injection lines 117 (e.g., one or more pipes) and / or valve 118 may be disposed downstream of outlet port 116. Asphalt pump 119 may be equipped with a VFD motor, controllable by controller 102 and interlocked with other plant components. For example, asphalt pump 119 may be disposed in series with heated injection line 117. Pump 119 may be configured to supply molten asphalt 113 to separation unit 114. Molten asphalt 113 may be metered to separation unit 114 via pump 119 under control of controller 102 and metered by a flow meter (not shown), and adjusted based on one or more factors such as the capacity and production rate of separation unit 114.

[0040] The separation unit 114 may include a tank 120 defining an inverted conical shape having an inner diameter toward its top portion that is larger than an inner diameter toward its bottom portion. The separation unit 114 may include an inlet port 121 connected to the tank 120 and configured to receive the molten asphalt 113 from the mixing unit 104 via a heated injection line 117. The separation unit 114 may further include a heating mechanism 122 configured to heat the molten asphalt 113 in the tank 120.

[0041] When molten asphalt 113 is received in separation unit 114, it is desirable to maintain the molten asphalt heated to a specific temperature via heating mechanism 122. In some exemplary embodiments, heating mechanism 122 is similar to heater 106 of mixing unit 104. However, in other exemplary embodiments, heating mechanism 122 of separation unit 114 is different from heater 106 of mixing unit 104. For example, tank 120 of separation unit 104 may include an inner surface 123 and an outer surface 124 that contact molten asphalt 113. A chamber 125 may be defined between inner surface 123 and outer surface 124. A certain amount of heating oil may be continuously circulated in chamber 125 of tank 120 to maintain the temperature of molten asphalt 113 in tank 120 at approximately 250 degrees Fahrenheit to approximately 350 degrees Fahrenheit. Insulation material may further be provided on outer surface 124 and / or inner surface 123 to further insulate and maintain molten asphalt 113 at a desired temperature.

[0042] Separation unit 114 may include one or more mechanisms to separate molten pitch 113 into its constituent components, namely, fluid pitch 126 and solid material 127. Thus, separation unit 114 may include one or more filters, one or more centrifugal pumps, etc. Alternatively, or in addition, the mechanism may be a more passive separation mechanism. For example, tank 120 may be oriented so that the central axis of tank 114 is oriented vertically, and the inverted conical shape of tank 120 thus allows gravity to separate molten pitch 113 into fluid pitch 126 that rises toward the top portion of tank 120 and solid material 127 that settles toward the bottom portion of tank 120. Any other type of separation mechanism is also contemplated herein.

[0043] Separation unit 114 may further include a first outlet port 128 connected toward the top portion of tank 120 and configured to output fluid pitch 126 separated from solid material 127 of molten pitch 113, and a second outlet port 129 connected at the bottom portion of tank 120 and configured to output solid material 127 that has settled toward the bottom portion of tank 120. In some example embodiments, separation unit 114 includes a third outlet port 130 connected to tank 120. Third outlet port 130 may be connected above or below inlet port 121 (i.e., somewhere between first outlet port 128 and second outlet port 129), wherein first outlet port 128 is configured to output a first amount of fluid pitch to storage tank 131, and third outlet port 130 is configured to output a second amount of fluid pitch (i.e., fluid pitch input 112) to mixing unit 104.

[0044] Regarding the first outlet port 128 of the separation unit 114, a first amount of fluid asphalt continuously flowing toward the top portion of the tank 120 can be directed to the tank 131 through the first outlet port 128. One or more heated injection lines 132 (e.g., one or more pipes) and / or a valve 133 can be disposed downstream of the first outlet port 128. A pump 134, which can be equipped with a VFD motor, can be controlled by the controller 102 and interlocked with other plant components. For example, the pump 134 can be disposed downstream of the first outlet port 128 and connected to the heated injection line 132. The pump 134 can be configured to siphon the first amount of fluid asphalt from the top portion of the separation tank 114 and direct it to the storage tank 131. Under the control of the controller 102 and metered by a flow meter (not shown), the first amount of fluid asphalt can be metered into the storage tank 131 through the pump 134 and adjusted based on one or more factors such as, for example, the capacity of the storage tank 131, the production rate, etc.

[0045] As for the second outlet port 129 of the separation unit 114, the second outlet port 129 can define an eight (8) to ten (10) inch opening through which the solid material 127 exits after settling toward the bottom portion of the tank 120. One or more valves 135 can be disposed downstream of or at the second outlet port 129 to selectively direct / control (e.g., via the controller 102) the output of the solid material 127 therethrough and into a transportable container 136 disposed downstream of the separation unit 114. The transportable container 136 can comprise a trailer or truck bed that can transport the solid material 127 to a desired location. The solid material 127 can comprise sand, crushed aggregate, gravel, etc., with a particle size not exceeding 1 / 8 inch. The solid material 127 can be primarily composed of solid particles, but a certain small amount of fluid asphalt can be present in the solid material 127. In this manner, solid material 127 may be metered into transportable container 136 via valve 135 and adjusted based on one or more factors such as, for example, the capacity of transportable container 136, production rate, and the like.

[0046] Further, with respect to the third outlet port 130 of the separation unit 114, the second amount of fluid asphalt can be directed back to the mixing unit 104 through the third outlet port 130. One or more heated injection lines 137A, 137B (e.g., one or more pipes) and / or a valve 138 can be arranged downstream of the third outlet port 130. For example, when the third outlet port 130 is located above the first inlet port 121, the heated injection line 137B is arranged downstream of the third outlet port 130. In another example, when the third outlet port 130 is located below the first inlet port 121, the heated injection line 137A is arranged downstream of the third outlet port 130. A pump (not shown) that can be equipped with a VFD motor can be controlled by the controller 102 and interlocked with other plant components. For example, the pump can be arranged downstream of the third outlet port 130 and connected to the heated injection line 137A or 137B. The pump can be configured to siphon any fluid asphalt trapped in the solid material from the bottom portion of the separation tank 114 and direct it to the mixing unit 104, such that a second amount of fluid asphalt defines the fluid asphalt input 112 in the mixing unit 104. Thus, the second amount of fluid asphalt can be metered to the mixing unit 104 via the pump under the control of the controller 102 and measured by a flow meter (not shown), and adjusted based on one or more factors such as, for example, moisture content, residual asphalt content, mixture production rate, and the percentage of the total asphalt mixture defined by the asphalt shingle input 107 in the mixing unit 104. In this manner, the mixing unit 104 can mix and heat the fluid asphalt input 112 (i.e., the second amount of fluid asphalt) with the asphalt shingle input 107 to produce molten asphalt 113.

[0047] As the molten asphalt 113 is directed from the mixing unit 104 to the separation tank 114, it is continuously stirred by at least one circulation blade 141 disposed in the separation tank 114. The circulation blade 141 may be disposed toward the top of the separation tank 11. Other types of mixers may also be used alone or in combination with the at least one circulation blade 141.

[0048] Turning now to storage tank 131, storage tank 131 may be configured to receive and store fluid asphalt (i.e., a first amount of fluid asphalt) 126 output from separation unit 114. Storage tank 131 may comprise a large capacity tank, e.g., a 30,000 gallon tank, that can store fluid asphalt 126 at a desired temperature (e.g., about 400 to about 350 degrees Fahrenheit) until it is siphoned out and transported for secondary use. In some example embodiments, storage tank 131 includes an inlet port 139 that is in communication with heated injection line 132. Valve 133 may be located upstream of inlet port 139 and may be configured to filter out large particles (e.g., rocks) and / or solid matter. Further, storage tank 131 may be covered (e.g., by a lid) to prevent water from entering therein.

[0049] It is noteworthy that each of the pipes and other components that handle the fluid materials described herein can be heated. For example, a heated fluid (e.g., oil or steam) can be circulated between the components to maintain the fluidity of the asphalt material (e.g., molten asphalt 113, fluid asphalt 126). For example, each pipe that transports a fluid asphalt material can include an outer pipe surrounding an inner pipe. The inner pipe can transport the asphalt material (e.g., molten asphalt 113), and the outer pipe can transport a heated fluid (e.g., oil or steam) to heat the asphalt material received in the inner pipe to maintain its fluidity.

[0050] Figure 2 A second example embodiment of a system 200 for recycling asphalt shingles to produce fluid asphalt and solid material is shown. Figure 2 Can be used with Figure 1 The system 100 described in Figure 2 The reference numerals shown in the figures are those associated with the different elements between the first and second embodiments. For example, Figure 2 and Figure 1 The difference is that the pipeline 137B is not included, and the pipeline 117 ( Figure 2 217) are connected to the separation unit 114 ( Figure 2 In addition, new piping associated with the storage tank 231 is also shown.

[0051] In particular, a heated injection line 217 (e.g., one or more pipes) and / or a valve 218 may be disposed downstream of the outlet port 216 of the mixing unit 104. For example, an asphalt pump 219, which may be equipped with a VFD motor, may be controlled by the controller 102 and interlocked with other plant components. For example, the asphalt pump 219 may be disposed in conjunction with the heated injection line 217. The pump 219 may be configured to supply molten asphalt 113 to the separation unit 214. The molten asphalt 113 may be metered from the pump 219 to the separation unit 214 under the control of the controller 102 and measured by a flow meter (not shown), and adjusted based on one or more factors such as, for example, the capacity and production rate of the separation unit 214.

[0052] The separation unit 214 may include a tank 120 defining an inverted cone having an inner diameter toward its top portion that is larger than an inner diameter toward its bottom portion. The separation unit 214 may include an inlet port 221 connected to the tank 120 and configured to receive the molten asphalt 113 from the mixing unit 104 through the heating injection line 217. The separation unit 214 may further include a heating mechanism 122 configured to heat the molten asphalt 113 in the tank 120. The inlet port 221 may be arranged above or below the circulation blade 241 in the separation unit 214. Figure 2 As shown in FIG, the inlet port 221 is arranged above the circulation blade 241.

[0053] Figure 2 231. The pipe 240 may be disposed within the storage tank 231 and in fluid communication with the heated injection line 232. The pipe 240 may be a heated line that receives the fluid asphalt 126 from the separation unit 214 and directs it toward the bottom of the storage tank 231. Thus, the pipe 240 is connected to the heated injection line 232 at the inlet port 239. In some exemplary embodiments, and as shown in FIG. Figure 2As shown in FIG, conduit 240 is U-shaped. In this example, a first vertical portion of U-shaped conduit 240 may include an inlet portion connected to inlet port 239. Fluid asphalt 126 may be pumped through inlet port 239 and upward along the first vertical portion of conduit 240, for example, via pump 234. A curved portion of U-shaped conduit 240 may be disposed at the end of the first vertical portion of U-shaped conduit 240, causing U-shaped conduit 240 to curve downward toward the bottom of storage tank 231. A second vertical portion of U-shaped conduit 240 may include an end portion disposed in fluid communication with the curved portion and extending vertically downward toward the bottom of storage tank 231. An outlet portion 240A of U-shaped conduit 240 may be the location where fluid asphalt 126 is deposited in storage tank 231. Other shapes, lengths, widths, etc. of conduit 240 are also contemplated by this disclosure. Notably, one or more openings may be provided in the first and / or second vertical portions of conduit 240 to facilitate the exit of fluid asphalt 126 from the conduit when storage tank 231 is filled with fluid asphalt.

[0054] like Figure 3 As shown in FIG, a method for producing an asphalt mixture is also provided. The method is generally referred to as method 300. Method 300 includes: a first step 302, comprising heating an asphalt shingle input from a first source in a mixing unit to melt the asphalt shingle input and produce molten asphalt; a second step 304, comprising directing the molten asphalt to a separation unit; a third step 306, comprising separating the molten asphalt into a solid material and a fluid asphalt in the separation unit; and a fourth step 308, comprising receiving and storing the fluid asphalt in a storage tank.

[0055] Figure 4 An embodiment of a controller, generally designated 400, is schematically shown, such as, Figure 1 and Figure 2Controller 400 may be configured to execute computer code for performing the operations described herein. Thus, controller 400 may include processor 402, which may be a microprocessor or controller for controlling its overall operation. In one embodiment, processor 402 may be specifically configured to execute program code instructions related to the functions described herein, including operations for forming molten asphalt 113 from asphalt shingle input 107, separating molten asphalt 113, and delivering fluid asphalt 126 to storage tank 131. Controller 400 may also include storage device 404. Storage device 404 may include non-transitory tangible memory, such as volatile and / or non-volatile memory. Storage device 404 may be configured to store information, data, files, applications, instructions, and the like. For example, storage device 404 may be configured to buffer input data for processing by processor 402. Additionally or alternatively, storage device 404 may be configured to store instructions for execution by processor 402.

[0056] The controller 400 may further include a user interface 406 that allows a user to interact with it. For example, the user interface 406 may take various forms, such as buttons, keypads, dials, touch screens, audio input interfaces, visual / image capture input interfaces, inputs in the form of sensor data, etc. Further still, the user interface 406 may be configured to output information to the user via a display, speaker, or other output device. A communication interface 408 may be provided for transmitting and receiving data via, for example, a wired or wireless network 410, such as a local area network (LAN), a metropolitan area network (MAN), and / or a wide area network (WAN) (e.g., the Internet). The communication interface 408 may enable the controller 400 to communicate directly or via a network 410 with one or more other computing devices. In this way, the communication interface 408 may include one or more interface mechanisms for communicating with other devices and / or networks. The communication interface 408 may accordingly include one or more interface mechanisms, such as an antenna (or multiple antennas) and supporting hardware and / or software for enabling communication via wireless communication technologies (e.g., cellular technologies, wireless communication technologies, Wi-Fi and / or other IEEE 802.11 technologies, Bluetooth, Zigbee, wireless USB, NFC, RF-ID, WiMAX and / or other IEEE 802.16 technologies, and / or other wireless communication technologies), and / or a communication modem or other hardware / software for supporting communication via cable, digital subscriber line (DSL), USB, FireWire, Ethernet, one or more optical transmission technologies, and / or other wired network methods. Further, the controller 400 may include a mixing module 412. For example, the mixing module 412 may be configured to, in conjunction with the processor 402, direct operations for forming the molten asphalt 113 from the asphalt shingle input 107, separating the molten asphalt 113, etc., as described herein.

[0057] The various aspects, embodiments, implementation methods or features of the described embodiments may be used alone or in any combination. The various aspects of the described embodiments may be performed by software, hardware or a combination of hardware and software. The described embodiments may also be implemented as computer-readable code on a computer-readable medium for controlling the above-mentioned operations. Specifically, the computer-readable code may be configured to perform each of the operations of the methods described herein and embodied as computer-readable code on a computer-readable medium for controlling the above-mentioned operations. Thus, a computer-readable storage medium as used herein refers to a non-temporary, physical storage medium (e.g., a volatile or non-volatile memory device) that can be read by a computer system. Examples of computer-readable media include read-only memory, random access memory, CD-ROM, DVD, magnetic tape and optical data storage devices. The computer-readable medium may also be distributed on a network-connected computer system so that the computer-readable code is stored and executed in a distributed manner.

[0058] As described above, the controller 400 can be configured to execute computer code for performing the mixing operations described above. Thus, an embodiment of a non-transitory computer-readable medium is provided for storing computer instructions executed by a processor in a controller (e.g., the controller 400), the computer instructions configured to form molten asphalt 113 from the asphalt shingle input 107. Thus, the non-transitory computer-readable medium can include program code instructions for performing the operations disclosed herein.

[0059] It is noted that while the apparatus, systems, and methods provided herein are generally described as being used to recycle asphalt shingles, such apparatus, systems, and methods can also be used to recycle other asphalt-based products. For example, the apparatus, systems, and methods of the present disclosure can be used to produce asphalt shingles. Thus, the apparatus, systems, and methods of the present disclosure are configured to recycle any asphalt-based product into a form that can be used as input for the production of any asphalt-based product.

[0060] Many modifications and other embodiments of the present disclosure will occur to those skilled in the art to which this disclosure relates, having the benefit of the teachings provided in the foregoing description; changes and modifications to the present disclosure will be apparent to those skilled in the art without departing from the scope and spirit of the present disclosure. Therefore, it is to be understood that this disclosure is not limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A method for recycling asphalt shingles, the method comprising: heating an asphalt shingle input from a first source in a mixing unit to melt the asphalt shingle input and produce molten asphalt; directing the molten asphalt into a separation unit; separating the molten asphalt into solid material and fluid asphalt in the separation unit; as well as The fluid asphalt is received and stored in a storage tank.

2. The method of claim 1 , further comprising directing a first amount of the fluid asphalt from the separation unit to the storage tank, and directing a second amount of the fluid asphalt from the separation unit to the mixing unit or directing an amount of raw fluid asphalt from a raw fluid asphalt source to the mixing unit.

3. The method of claim 2, further comprising mixing and heating the second amount of the fluid asphalt with the asphalt shingle input in the mixing unit to produce the molten asphalt.

4. The method of claim 1, further comprising grinding a plurality of asphalt shingles to produce the asphalt shingle input. 5 . The method according to claim 1 , further comprising stirring the molten asphalt in the mixing unit by at least one circulation blade disposed in the mixing unit.

6. The method of claim 1, further comprising directing the solid material into a transportable container disposed downstream of the separation unit.

7. A method according to claim 1, wherein the separation unit includes an inverted cone having an inner diameter toward its top portion that is larger than an inner diameter toward its bottom portion, and wherein separating the molten asphalt into solid material and fluid asphalt includes allowing the solid material to settle toward the bottom portion of the separation unit and allowing the fluid asphalt to remain toward the top portion of the separation unit.

8. A separation unit comprising: a tank defining an inverted cone having an inner diameter toward a top portion thereof that is greater than an inner diameter toward a bottom portion thereof; an inlet port connected to the tank and configured to receive molten asphalt; a first outlet port connected toward a top portion of the tank and configured to output fluid asphalt separated from solid matter of the molten asphalt; a second outlet port connected at the bottom portion of the tank and configured to output the solid matter settled toward the bottom portion of the tank; as well as A heating mechanism is configured to heat the molten asphalt in the tank.

9. The separation unit of claim 8, further comprising a third outlet port connected to the tank between the first outlet port and the second outlet port, wherein the first outlet port is configured to output a first amount of the fluid asphalt to a storage tank, and in, The mixing unit is configured to receive the second amount of the fluid pitch output from the third outlet port or an amount of raw fluid pitch output from a source of raw fluid pitch.

10. The separation unit of claim 8, further comprising a valve disposed at the second outlet port and configured to selectively direct the solid material therethrough.

11. The separation unit of claim 8, further comprising a pump located downstream of the first outlet port.

12. The separation unit of claim 8 , wherein the tank comprises an inner surface and an outer surface in contact with the molten asphalt and having a chamber defined therebetween, and the heating mechanism comprises a quantity of heating oil circulated within the chamber of the tank to maintain the temperature of the molten asphalt in the tank at a range of about 250 degrees Fahrenheit to about 350 degrees Fahrenheit.

13. A system for reusing asphalt shingles, the system comprising: a mixing unit arranged to receive an asphalt shingle input from a first source, the mixing unit configured to heat and melt the asphalt shingle input and produce molten asphalt; a separation unit arranged to receive the molten asphalt and separate the molten asphalt into solid material and fluid asphalt; and A storage tank is configured to receive and store the fluid asphalt output from the separation unit.

14. The system of claim 13, further comprising a grinder configured to grind a plurality of asphalt shingles to produce the asphalt shingle input.

15. The system of claim 13, further comprising at least one circulation blade disposed in the mixing unit to stir the molten asphalt in the mixing unit.

16. The system of claim 13, wherein the separation unit comprises: a tank defining an inverted cone having an inner diameter toward its top portion that is greater than an inner diameter toward its bottom portion, an inlet port connected to the tank and configured to receive molten bitumen, a first outlet port connected toward a top portion of the tank and configured to output the fluid asphalt separated from the solid material of the molten asphalt to the storage tank, a second outlet port connected to the bottom portion of the tank and configured to output the solid material settled toward the bottom portion of the tank, and A heating mechanism is configured to heat the molten asphalt in the tank.

17. The system of claim 16, wherein the separation unit further comprises a third outlet port connected between the first outlet port and the second outlet port, wherein the first outlet port is configured to output a first amount of the fluid asphalt into the storage tank, and The mixing unit is configured to receive the second amount of the fluid asphalt output from the third outlet port or a certain amount of raw fluid asphalt output from a raw fluid asphalt source.

18. The system of claim 17, wherein the mixing unit is configured to mix and heat the second amount of the fluid asphalt with the asphalt shingle input to produce the molten asphalt.

19. The system of claim 17, further comprising a transportable container disposed adjacent the second outlet port of the separation unit and configured to collect the solid material that settles toward a bottom portion of the tank.

20. The system of claim 17, wherein the tank of the separation unit includes an inner surface and an outer surface in contact with the molten asphalt and having a chamber defined therebetween, and the heating mechanism includes a quantity of heating oil circulated in the chamber of the tank to maintain the temperature of the molten asphalt in the tank at about 250 degrees Fahrenheit to about 350 degrees Fahrenheit.

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